ULTRASONIC SURGICAL INSTRUMENTS WITH CONTROL MECHANISMS

• US 20140005681A1
• Filed: 06/29/2012
• Published: 01/02/2014
• Est. Priority Date: 06/29/2012
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon Endo-Surgery, Inc. (Johnson & Johnson)
• Inventors: Gee, Jacob S., Stulen, Foster B., Houser, Kevin L., Faller, Craig N., Strobl, Geoffrey S., Rhee, Sora, Dannaher, William D., Worrell, Barry C., Johnson, Gregory W.
• Granted Patent: US 9,820,768 B2
• Time in Patent Office: Days
• US Class Current: 606/130
• CPC Class Codes: A61B 17/320092 with additional movable means for clamping or cutting tissue, e.g. with a pivoting jaw
• CPC Class Codes: A61B 2017/003 Steerable
• CPC Class Codes: A61B 2017/00305 Constructional details of the flexible means
• CPC Class Codes: A61B 2017/00323 Cables or rods
• CPC Class Codes: A61B 2017/00327 with actuating members moving in opposite directions
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2017/00734 battery operated
• CPC Class Codes: A61B 2017/22015 with details of the transmission member
• CPC Class Codes: A61B 2017/22018 segmented along its length
• CPC Class Codes: A61B 2017/320071 with articulating means for working tip
• CPC Class Codes: A61B 2017/320093 additional movable means performing cutting operation
• CPC Class Codes: A61B 2017/320094 additional movable means performing clamping operation
• CPC Class Codes: A61B 2017/320095 with sealing or cauterizing means
• CPC Class Codes: A61B 2090/508 with releasable brake mechanisms
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: A61B 34/71 Manipulators operated by drive cable mechanisms
• CPC Class Codes: A61F 9/00745 using mechanical vibrations, e.g. ultrasonic

Abstract

Various embodiments are directed to surgical instruments for use in handheld applications or with robotic surgical systems. The surgical instruments may comprise an end effector to treat tissue and a shaft extending proximally from the end effector along a longitudinal axis. Some embodiments may be usable with an instrument mounting portion of a robotic surgical instrument. For example, the shaft may extend proximally to the instrument mounting portion.

Claims

1. A surgical instrument for use with a robotic surgical system, the surgical instrument comprising:

an end effector to treat tissue;

a shaft extending proximally from the end effector along a longitudinal axis;

a housing, wherein the shaft is coupled to a distal end of the housing;

a first magnetic element positioned within the housing;

a first cable coupled to the first magnetic element and extending distally from the first magnetic element and distally through the shaft such that actuation of the magnetic element causes the first cable to translate along the longitudinal axis;

a rotatable body positioned within the housing; and

an actuation member extending from the rotatable body to a switch of the first magnetic element such that rotation of the rotatable body alternately transitions the switch from a first position where the first magnetic element is actuated to a second position where the first magnetic element is not actuated.

2. The surgical instrument of claim 1, further comprising:

a second magnetic element positioned within the housing; and

a second cable coupled to the second magnetic element and extending distally from the second magnetic element and distally through the shaft such that actuation of the second magnetic element causes the second cable to translate along the longitudinal axis; and

a second actuation member extending from the rotatable body to a switch of the second magnetic element such that rotation of the rotatable body alternately transitions the switch of the second magnetic element from a first position where the second magnetic element is actuated to a second position where the second magnetic element is not actuated.

3. The surgical instrument of claim 2, wherein the rotatable body is rotatable to a first position where both the first and second magnetic elements are not actuated;

to a second position where the first magnetic element is actuated and the second magnetic element is not actuated; and

to a third position where the first and second magnetic elements are not actuated.

4. The surgical instrument of claim 2, further comprising:

a third magnetic element positioned within the housing; and

a third cable coupled to the third magnetic element and extending distally from the third magnetic element and distally through the shaft such that actuation of the second magnetic element causes the second cable to translate along the longitudinal axis; and

a third actuation member extending from the rotatable body to a switch of the third magnetic element such that rotation of the rotatable body alternately transitions the switch of the third magnetic element from a first position where the third magnetic element is actuated to a second position where the third magnetic element is not actuated.

5. The surgical instrument of claim 4, wherein the rotatable body is rotatable:

to a first position where the first, second and third magnetic elements are actuated;

to a second position where the first and second magnetic elements are actuated and the third magnetic element is not actuated;

to a third position wherein the first magnetic element is actuated and the second and third magnetic elements are not actuated; and

to a fourth position where the first, second and third magnetic elements are not actuated.

6. The surgical instrument of claim 5 wherein the rotatable body is rotatable:

to a fifth position where the first and second magnetic elements are not actuated and the third magnetic element is actuated;

to a sixth position where the first magnetic element is not actuated and the second and third magnetic elements are actuated.

7. The surgical instrument of claim 1, further comprising:

a second magnetic element positioned within the housing;

a second cable coupled to the second magnetic element and extending distally from the second magnetic element and distally through the shaft such that actuation of the second magnetic element causes the second cable to translate along the longitudinal axis;

a second rotatable body positioned within the housing; and

a second actuation member extending from the second rotatable body to a switch of the second magnetic element such that rotation of the rotatable body alternately transitions the switch of the second magnetic element from a first position where the second magnetic element is actuated to a second position where the second magnetic element is not actuated.

8. The surgical instrument of claim 1, wherein the shaft comprises a flexible articulation joint, and wherein the first cable is coupled to the shaft distally from the flexible articulation joint and offset from the longitudinal axis such that proximal translation of the first cable causes pivoting of the end effector away from the longitudinal axis towards the first cable.

9. The surgical instrument of claim 8, wherein the end effector comprises an ultrasonic blade, further comprising a transducer assembly positioned distally from the flexible articulation joint and acoustically coupled to the ultrasonic blade.

10. The surgical instrument of claim 1, wherein a proximal portion of the shaft extends proximally along the longitudinal axis within the housing, and further comprising:

a second magnetic element positioned within the housing;

a second cable having a proximal end coupled to the second magnetic housing and a distal end positioned around the proximal portion of the shaft, wherein actuation of the second magnetic element unwraps the second cable from the proximal portion of the shaft, causing rotation of the shaft.

11. The surgical instrument of claim 1, further comprising:

a second rotatable body; and

a second cable coupled to the second rotatable body and extending distally from the first rotatable body through the shaft such that rotation of the second rotatable body causes the second cable to translate along the longitudinal axis.

41. The surgical instrument of claim 1, wherein the rotatable member defines a convex face, and wherein at the first angular position, the convex face faces the first post.

12. A surgical instrument for use with a robotic surgical system, the surgical instrument comprising:

an end effector to treat tissue;

a shaft extending proximally from the end effector along a longitudinal axis;

a housing, wherein the shaft is coupled to a distal end of the housing;

a first rotatable body positioned within the housing, wherein the first rotatable body comprises a first peg offset from a center of rotation of the first rotatable body;

a second rotatable body positioned within the housing, wherein the second rotatable body comprises a second peg offset from a center of rotation of the second rotatable body;

an elastic band coupled to the first peg and the second peg; and

a cable coupled to the elastic band and extending distally through the shaft, wherein rotation of the first and second rotatable bodies that moves the first and second pegs proximally also pulls the elastic band and cable proximally.

13. The surgical instrument of claim 12, wherein rotation of the first and second rotatable bodies that moves the first and second pegs distally also pushes the elastic band and cable proximally.

14. A surgical instrument for use with a robotic surgical system, the surgical instrument comprising:

an end effector to treat tissue;

a shaft extending proximally from the end effector along a longitudinal axis;

a housing, wherein the shaft is coupled to a distal end of the housing;

a first rotatable body positioned within the housing, wherein the first rotatable body comprises a first peg offset from a center of rotation of the first rotatable body;

a second rotatable body positioned within the housing, wherein the second rotatable body comprises a second peg offset from a center of rotation of the second rotatable body, and where a rotational axis of the first rotatable body is positioned distally from a rotational axis of the second rotatable body; and

a cable fixedly secured to an interior portion of the housing, routed by the first and second pegs, and extending distally through the shaft such that rotation of the first and second rotatable bodies causes the cable to translate along the longitudinal axis.

15. A surgical instrument comprising:

an end effector comprising an ultrasonic blade;

a shaft extending proximally from the end effector along a longitudinal axis, the shaft defining a flexible articulation joint;

a waveguide extending proximally from the ultrasonic blade through the shaft, wherein the waveguide defines a bendable portion at about the flexible articulation joint;

a first plate positioned distally from the flexible articulation joint at a node of at least one of the waveguide and the ultrasonic blade;

a first helical cable coupled to the first plate at a first point offset from the longitudinal axis and extending proximally;

a second helical cable coupled to the first plate at a second point offset from the longitudinal axis and extending proximally;

a gear, positioned proximally from the flexible articulation joint, wherein a first side of the gear interlocks with the first helical cable and a second side of the gear interlocks with the second helical cable such that rotation of the gear causes differential translation of the first and second helical cables.

16. The surgical instrument of claim 15, wherein rotation of the gear in a first direction causes proximal translation of the first cable, pivoting the first plate and end effector away from the longitudinal axis towards the first cable.

17. The surgical instrument of claim 16, wherein rotation of the gear in a second direction causes proximal translation of the second cable, pivoting the first plate and end effector away from the longitudinal axis towards the second cable.

18. The surgical instrument of claim 15, further comprising a housing for interfacing with a robotic surgical system, wherein the gear is coupled to a rotatable body positioned within the housing.

19. The surgical instrument of claim 15, further comprising a handle comprising an articulation lever coupled to the gear.

20. A surgical instrument for use with a robotic surgical system, the surgical instrument comprising:

an end effector to treat tissue, the end effector comprising an ultrasonic blade;

a shaft extending proximally from the end effector along a longitudinal axis;

an ultrasonic transducer coupled to a proximal end of the shaft;

a waveguide acoustically coupled to the ultrasonic transducer and the ultrasonic blade and extending through the shaft; and

a housing, wherein the shaft extends through the housing, and wherein the shaft, ultrasonic transducer, waveguide, and end effector are translatable distally and proximally along the longitudinal axis.

21. The surgical instrument of claim 20, further comprising:

a rack gear coupled to the shaft at a portion of the shaft within the housing; and

a rotatable body positioned within the housing; and

a gear coupled to the rotatable body and interfaced with the rack gear such that rotation of the gear translates the shaft ultrasonic transducer, waveguide and end effector distally and proximally along the longitudinal axis.

22. The surgical instrument of claim 20, further comprising a robotic manipulator arm, wherein the housing is coupled to the robotic manipulator arm, and wherein the manipulator arm comprises a trocar mounted distally from the housing, wherein the shaft extends through the trocar.

23. A surgical instrument comprising:

an end effector to treat tissue;

a shaft extending proximally from the end effector along a longitudinal axis, wherein the shaft comprises;

a proximal tube defining a first channel positioned near an interior wall of the proximal tube;

a distal tube, wherein the end effector is coupled to a distal portion of the distal tube; and

a flexible articulation portion positioned between the proximal tube and the distal tube;

a first articulation cable coupled to at least one of the end effector and the distal tube and extending proximally through the first channel of the proximal tube such that proximal translation of the first articulation cable pulls the distal tube and the end effector away from the longitudinal axis towards the first articulation cable.

24. The surgical instrument of claim 23, wherein the proximal tube further defines a second channel positioned near an interior wall of the proximal tube and offset from the first channel about the longitudinal axis, wherein the surgical instrument further comprises:

a second articulation cable coupled to at least one of the end effector and the distal tube and extending proximally through the second channel of the proximal tube such that proximal translation of the second articulation cable pulls the distal tube and the end effector away from the longitudinal axis towards the second articulation cable.

25. The surgical instrument of claim 23, wherein the first articulation cable comprises two cables braided to one another.

26. The surgical instrument of claim 23, wherein the first channel is defined by a coil pipe welded to the interior wall of the proximal tube.

27. The surgical instrument of claim 23, wherein the first channel extends distally beyond the interior wall of the proximal tube.

28. The surgical instrument of claim 23, wherein the flexible articulation portion defines a second channel aligning with the first channel for receiving the first articulation cable.

29. A surgical instrument for use with a robotic surgical system, the surgical instrument comprising:

an end effector to treat tissue, the end effector comprising at least one energy element for providing energy to the tissue;

a shaft extending proximally from the end effector along a longitudinal axis;

a housing, wherein the shaft is coupled to a distal portion of the housing; and

a battery assembly for powering the at least one energy element, wherein the battery assembly comprises;

a rechargeable battery positioned within the housing, wherein the rechargeable battery is electrically coupled to the at least one energy element; and

an inductive coil coupled to the rechargeable battery, wherein the inductive coil is positioned to be placed in proximity with a second inductive coil providing electrical energy for recharging the battery.

30. The surgical instrument of claim 29, wherein the at least one energy element comprises an ultrasonic blade, and wherein the rechargeable battery is electrically coupled to a transducer in ultrasonic communication with the ultrasonic blade.

31. The surgical instrument of claim 29, further comprising a generator circuit positioned within the housing to generate at least one drive signal for the at least one energy element.

32. The surgical instrument of claim 29, further comprising a sensor electrically positioned to sense at least one charge property of the rechargeable battery, wherein the sensor is in electrical communication with a communications bus of the robotic surgical system to provide the at least one charge property of the rechargeable battery to a surgeon display of the robotic surgical instrument.

33. The surgical instrument of claim 29, further comprising:

a foot pedal in electrical communication with a transmitter;

a receiver in electrical communication with the at least one energy element, wherein, upon receipt of a signal from the transmitter indicating that the foot pedal has been actuated, the receiver is to send a signal to actuate the at least one energy element.

34. A surgical instrument for use with a robotic surgical system, the surgical instrument comprising:

an end effector to treat tissue, the end effector comprising at least one energy element for providing energy to the tissue;

a shaft extending proximally from the end effector along a longitudinal axis;

a housing, wherein the shaft is coupled to a distal portion of the housing; and

a power cord electrically coupled to the at least one energy element and extending from the housing, wherein the power cord comprises therein a generator for providing a drive signal to the at least one energy element.

35. The surgical instrument of claim 34, wherein the at least one energy element comprises an ultrasonic blade.

a battery assembly for powering the at least one energy element, wherein the battery assembly comprises:

a rechargeable battery positioned within the housing, wherein the rechargeable battery is electrically coupled to the at least one energy element; and

an inductive coil coupled to the rechargeable battery, wherein the inductive coil is positioned to be placed in proximity with a second inductive coil providing electrical energy for recharging the battery.

36. A surgical instrument for use with a robotic surgical system, the surgical instrument comprising:

an end effector to treat tissue, the end effector comprising at least one energy element for providing energy to the tissue;

a shaft extending proximally from the end effector along a longitudinal axis;

a housing, wherein the shaft is coupled to a distal portion of the housing, and wherein the housing defines an exterior socket; and

a removable battery assembly for powering the at least one energy element, wherein the removable battery assembly is receivable into the exterior socket of the housing to be in electrical communication with the at least one energy element.

37. The surgical instrument of claim 36, further comprising:

a foot pedal in wireless electrical communication with a transmitter;

a receiver in wireless electrical communication with the transmitter and in communication with at least one energy element, wherein, upon receipt of a signal from the transmitter indicating that the foot pedal has been actuated, the receiver is to send a signal to actuate the at least one energy element.

38. The surgical instrument of claim 36, wherein the removable battery assembly further comprises a generator circuit to generate at least one drive signal for the at least one energy element.

39. A surgical instrument comprising:

an end effector to treat tissue;

a shaft extending proximally from the end effector along a longitudinal axis, wherein the shaft comprises;

a proximal tube;

a distal tube, wherein the end effector is coupled to a distal portion of the distal tube; and

a flexible articulation portion positioned between the proximal tube and the distal tube, wherein the flexible articulation portion comprises a plurality of interfacing joint members, and wherein each of the joint members define first and second channels;

a first articulation cable coupled to at least one of the end effector and the distal tube, wherein the first articulation cable extends through the first channels of the plurality of joint members;

a second articulation cable coupled to at least one of the end effector and the distal tube, wherein the second articulation cable extends through the second channels of the plurality of joint members, wherein the first and second articulation cables are transitionable between an unlocked position where the first and second cables are free to translate distally and proximally and the plurality of joint members are slidable relative to one another to pivot the distal tube and end effector away from the longitudinal axis, and a locked position where translation of the first and second cables is locked, causing the position of the end effector and distal tube relative to the longitudinal axis to also be locked.

40. The surgical instrument of claim 39, further comprising a proximally positioned lock assembly, wherein the lock assembly comprises:

a first post;

a second post;

a rotatable member positioned between the first and second posts, wherein the first articulation cable is routed between the first post and the rotatable member, wherein the second articulation cable is routed between the second post and the rotatable member, wherein the rotatable member comprises a first angular position at which the first articulation cable is passable between the rotatable member and the first post and the second articulation cable is passable between the rotatable member and the second post, and wherein the rotatable member comprises a second angular position at which the first articulation member is locked between the rotatable member and the first post and the second articulation member is locked between the rotatable member and the second articulation member.