Fusing and cutting surgical instrument and related methods

• US 9,055,961 B2
• Filed: 02/17/2012
• Issued: 06/16/2015
• Est. Priority Date: 02/18/2011
• Status: Active Grant

• Current Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Original Assignee: Intuitive Surgical Operations, Inc. (Intuitive Surgical Holdings, LLC)
• Inventors: Manzo, Scott E., Kerver, Lawrence
• Primary Examiner(s): GETZOW, SCOTT M
• Application Number:
  US13/399,391
• Publication Number:
  US 20120215220A1
• Time in Patent Office: 1,215 Days
• Field of Search: 606 27- 52
• US Class Current: 1/1
• 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 18/1482 having a long rigid shaft for accessing the inner body transcutaneously in minimal invasive surgery, e.g. laparoscopy
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2018/00083 low, i.e. electrically insulating
• CPC Class Codes: A61B 2018/00607 Coagulation and cutting with the same instrument
• CPC Class Codes: A61B 2018/0063 Sealing
• CPC Class Codes: A61B 2018/00982 combined with or comprising means for visual or photographic inspections inside the body, e.g. endoscopes
• CPC Class Codes: A61B 2018/1452 including means for cutting A61B2018/146 takes precedence
• CPC Class Codes: A61B 2018/1455 having a moving blade for cutting tissue grasped by the jaws
• 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 surgical instrument can include a shaft having a proximal end and a distal end, and a wrist coupled to the distal end of the shaft and configured to articulate in multiple degrees of freedom coupled to the distal end of the shaft. The surgical instrument can further include an end effector supported by the wrist, wherein the end effector includes a cutting element and jaws configured to grip tissue and fuse tissue via electrosurgical energy. The surgical instrument can be configured for use with a teleoperated robotic surgical system that can include a patient side console configured to interface to actuate the surgical instrument and a surgeon side console configured to receive inputs from a surgeon to control the actuation of the surgical instrument.

Claims

1. A surgical instrument comprising:

a shaft having a proximal end and a distal end;

a wrist coupled to the distal end of the shaft and configured to articulate in multiple degrees of freedom; and

an end effector supported by the wrist, wherein the end effector comprises a cutting element and jaws configured to grip tissue and fuse tissue, and wherein the cutting element is configured to translate along a longitudinal direction of the jaws.

2. The surgical instrument of claim 1, further comprising a cutting element drive component configured to translate the cutting element.

3. The surgical instrument of claim 2, wherein the cutting element drive component is flexible.

4. The surgical instrument of claim 3, wherein the cutting element drive component is flexible in multiple degrees of freedom about a longitudinal axis of the drive component.

5. The surgical instrument of claim 2, wherein the cutting element drive component comprises a cable.

6. The surgical instrument of claim 2, wherein the cutting element drive component extends substantially centrally through the shaft and wrist from a proximal end of the surgical instrument to the end effector.

7. The surgical instrument of claim 2, wherein the cutting element comprises a cutting blade attached to a distal end of the cutting element drive component.

8. The surgical instrument of claim 7, wherein the cutting blade is housed within the end effector during translation of the cutting element.

9. The surgical instrument of claim 1, wherein the end effector further comprises opposing jaws configured in a closed position to grip tissue with a sufficient pressure to permit fusing of the tissue during delivery of energy to the tissue.

10. The surgical instrument of claim 1, further comprising electrodes for delivery of energy to fuse tissue, the electrodes being respectively associated with the opposing jaws.

11. The surgical instrument of claim 10, further comprising at least one spacer configured to maintain a gap between opposing surfaces of the electrodes when the jaws are in a closed position.

12. The surgical instrument of claim 10, wherein the energy comprises bipolar electrical energy.

13. The surgical instrument of claim 1, further comprising a torque drive component configured to transmit torque to move the opposing jaws between open and closed positions.

14. The surgical instrument of claim 13, wherein the torque drive component extends through the wrist and is configured to transmit the torque to move the opposing jaws while the wrist is articulated in at least one of pitch and yaw.

15. The surgical instrument of claim 13, further comprising a lead screw rotatable in response to the torque transmitted by the torque drive component, and a drive nut moveable along the lead screw in response to rotation of the lead screw, wherein movement of the drive nut along the lead screw moves the opposing jaws between the open and closed positions.

16. The surgical instrument of claim 15, wherein each of the opposing jaws is associated with a cam extension provided with a cam slot that receives a portion of the drive nut.

17. The surgical instrument of claim 13, wherein the torque drive component comprises a torque tube formed of multiple windings.

18. The surgical instrument of claim 17, wherein the multiple windings comprise at least two multiple windings comprising helical turns in differing directions.

19. The surgical instrument of claim 17, wherein the torque tube comprises an inner winding and an outer winding each comprising helical turns in a first direction, and a middle winding disposed between the inner and outer winding and comprising helical turns in a second direction opposite to the first direction.

20. The surgical instrument of claim 17, wherein the torque tube extends through the wrist and has a distal end coupled to a lead screw that is positioned distal to the wrist.

21. The surgical instrument of claim 1, further comprising a transmission mechanism at a proximal portion of the surgical instrument, the transmission mechanism being configured to receive one or more inputs and, in response to receiving the one or more inputs, to transmit one or more of a force and a torque to operate the end effector.

22. The surgical instrument of claim 1, wherein the surgical instrument is configured to interface with a robotic surgical system.

23. The surgical instrument of claim 1, wherein the wrist has an outer diameter ranging from about 5 mm to about 8.5 mm.

24. The surgical instrument of claim 1, wherein the shaft, wrist, and end effector are configured to roll about a longitudinal axis of the shaft.

30. A teleoperated robotic surgical system comprising:

the surgical instrument of claim 1;

a patient side console configured to interface with the surgical instrument to actuate the surgical instrument to perform one or more surgical procedures; and

a surgeon side console comprising one or more input devices configured to be manipulated by a surgeon and to transmit signals to control the surgical instrument at the patient side console.

31. The telerobotic surgical system of claim 30, further comprising one or more controllers configured to be in signal communication with the instrument at the patient side console and with the surgeon side console to control the actuation of the surgical instrument.

25. A method of operating a surgical instrument, the method comprising:

receiving at least one first input at a transmission mechanism disposed at a proximal portion of the surgical instrument to articulate a multiple degree-of-freedom articulable wrist of the surgical instrument in at least one of pitch and yaw;

transmitting one or more forces via the transmission mechanism to articulate the wrist in response to the first input;

receiving a second input at the transmission mechanism to open jaws of an end effector supported by the wrist;

transmitting torque via the transmission mechanism to a torque drive component to open the jaws;

receiving a third input at the transmission mechanism to close the jaws of the end effector;

transmitting torque via the transmission mechanism to the torque drive component to close the jaws to grip tissue between the jaws;

transmitting energy to the jaws to fuse the gripped tissue;

receiving a fourth input at the transmission mechanism to translate a cutting element of the end effector; and

transmitting a force to a cutting element drive component via the transmission mechanism to translate the cutting element along a longitudinal direction of the jaws of the end effector.

26. The method of claim 25, wherein transmitting the force to the cutting element drive component comprises translating a push force followed by a pull force.

27. The method of claim 25, wherein transmitting the force to the cutting element drive component to translate the cutting element occurs while the wrist is articulated in at least one of pitch and yaw relative to a longitudinal axis of a shaft of the surgical instrument to which the wrist is coupled.

28. The method of claim 25, wherein transmitting torque via the transmission mechanism to the torque drive component to open and close the jaws comprises transmitting torque to a torque tube disposed at least partially within the wrist.

29. The method of claim 25, wherein transmitting the one or more forces via the transmission mechanism to articulate the wrist comprises transmitting one or more forces via the transmission mechanism to exert tension in tendons associated with the wrist.

32. A surgical instrument comprising:

a shaft having a proximal end and a distal end;

a wrist coupled to the distal end of the shaft and configured to articulate in multiple degrees of freedom;

an end effector supported by the wrist, the end effector comprising jaws;

a first drive element extending from the proximal end of the shaft to the end effector, the first drive element being configured to transmit forces to move the jaws relative to each other between open and closed positions; and

a second drive element extending from the proximal end of the shaft to the end effector, the second drive element being configured to transmit forces to translate a cutting component of the end effector in a longitudinal direction relative to the jaws, wherein the cutting component is configured to translate independently of movement of the jaws.