Surgical instrument coupling mechanism

• US 7,947,050 B2
• Filed: 06/13/2007
• Issued: 05/24/2011
• Est. Priority Date: 09/09/2002
• Status: Active Grant

• Current Assignee: Auris Health, Inc. (Johnson & Johnson)
• Original Assignee: Hansen Medical Incorporated (Johnson & Johnson)
• Inventors: Lee, Woojin, Mazzuca, Michael J., Gorhan, Michael C.
• Primary Examiner(s): TRUONG, KEVIN THAO
• Application Number:
  US11/762,743
• Publication Number:
  US 20070239172A1
• Time in Patent Office: 1,441 Days
• Field of Search: 606/130, 600/101, 600/102, 600/109, 600/114, 600/229, 600/234, 600/235, 600/407, 600/429, 700/85, 700/245, 700/247
• US Class Current: 606/130
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2034/715 Cable tensioning mechanisms for removing slack
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: A61B 34/37 Master-slave robots A61B34/35 takes precedence
• CPC Class Codes: A61B 34/71 Manipulators operated by drive cable mechanisms
• CPC Class Codes: A61B 46/10 specially adapted for instruments, e.g. microscopes
• CPC Class Codes: A61B 90/361 Image-producing devices, e.g. surgical cameras

Abstract

A medical system and an integrated drape assembly for a medical system is provided. The medical system comprises a surgical instrument that carries a distal tool configured for performing a medical procedure on a patient, a drive unit configured for controlling the movement of the surgical instrument within at least one degree-of-freedom, a coupling mechanism through which the surgical instrument is operably coupled to the drive unit, and an integrated drape assembly having a drape insert through which the coupling mechanism is coupled to the surgical instrument, a sterile drape covering the coupling mechanism. The drape assembly may comprise a coupling element mounted within the drape insert. The coupling element may be configured for coupling a driver element of the medical system to a driven element of the medical system.

Claims

1. A medical system, comprising:

a surgical instrument configured for performing a medical procedure on a patient;

a drive unit configured for controlling movement of the surgical instrument within at least one degree-of-freedom;

a coupling mechanism through which the surgical instrument is operatively coupled to the drive unit; and

a sterile drape forming a sterile barrier between the coupling mechanism and the surgical instrument, the sterile drape having a drape insert integrated therein through which the coupling mechanism is operatively coupled to the surgical instrument.

2. The medical system of claim 1, wherein the drive unit is coupled to the coupling mechanism via external cabling.

3. The medical system of claim 1, wherein the coupling mechanism is mounted over a patient table, and the drive unit is mounted to the patient table.

4. The medical system of claim 1, further comprising a remote controller configured for directing the drive unit to control the movement of the surgical instrument within the at least one degree-of-freedom.

5. The medical system of claim 4, wherein the remote controller has a user interface for receiving commands from a user.

6. The medical system of claim 5, wherein movements made at the user interface correspond to movements of the surgical instrument.

7. The medical system of claim 4, wherein the remote controller is coupled to the drive unit via external cabling.

8. The medical system of claim 1, wherein the drive unit has a motor array.

9. The medical system of claim 1, wherein the drape insert is composed of a stiff material.

10. The medical system of claim 1, further comprising another coupling mechanism coupled directly to the drive unit, wherein the sterile drape further covers the other coupling mechanism.

11. The medical system of claim 1, wherein the surgical instrument is removably coupled to the coupling mechanism.

12. The medical system of claim 1, further comprising wherein the coupling mechanism has a driver element configured to be-actuated by the drive unit, the surgical instrument has a driven element configured to be actuated by the driver element to move the surgical instrument within the at least one degree-of-freedom, and the drape assembly has a coupling element mounted within the drape insert that mechanically couples the driver element to the driven element.

13. The medical system of claim 12, wherein each of the driver element, driven element, and coupling element is configured for rotating to move the surgical instrument within the at least one degree-of-freedom.

14. The medical system of claim 1, further comprising an instrument adapter in which the surgical instrument member is mounted, wherein the coupling mechanism is coupled to the adapter through the drape insert.

15. The medical system of claim 14, wherein the surgical instrument is removably received by the adapter.

16. The medical system of claim 15, wherein the coupling mechanism has a first driver element configured for being actuated by the drive unit, the adapter has a second driver element configured for being actuating by the first driver element, the surgical instrument has a driven element configured for being actuated by the second driver element to move the surgical instrument within the at least one degree-of-freedom, and the drape insert has a coupling element that mechanically couples the first driver element to the second driver element.

17. The medical system of claim 1, wherein the at least one degree-of-freedom is an actuation of a tool carried by the surgical instrument.

18. The medical system of claim 1, wherein the at least one degree-of-freedom comprises a plurality of degrees-of-freedom.

19. The medical system of claim 1, wherein the coupling mechanism has a guide tube through which the surgical instrument is disposed.

20. An integrated drape assembly for a medical system, comprising:

a sterile drape;

a drape insert integrated in the sterile drape; and

a coupling element mounted within the drape insert, wherein the coupling element is configured to couple a driver element of the medical system to a driven element of the medical system, with the sterile drape forming a sterile barrier between a first portion of the medical system having the driver element and a second portion of the medical system having the driven element.

21. The drape assembly of claim 20, wherein the drape insert is composed of a stiff material.

22. The drape assembly of claim 20, wherein the coupling element is rotatably mounted within the drape insert.

23. The drape assembly of claim 20, wherein the drape insert has a hole, and the coupling element has first and second portions mounted to the drape insert on opposite sides of the hole.

24. The drape assembly of claim 20, wherein the coupling element has a slot configured for receiving a blade of the driver element.

25. The drape assembly of claim 20, wherein the coupling element has a slot configured for receiving a blade of the driven element.