Articulating surgical instruments and method of deploying the same

• US 9,517,059 B2
• Filed: 05/20/2014
• Issued: 12/13/2016
• Est. Priority Date: 05/20/2013
• Status: Active Grant

• Current Assignee: Endobotics, LLC
• Original Assignee: Medrobotics Corp.
• Inventors: Castro, Michael Salvatore
• Primary Examiner(s): Shi, Katherine M
• Assistant Examiner(s): GABR, MOHAMED GAMIL
• Application Number:
  US14/888,541
• Publication Number:
  US 20160074028A1
• Time in Patent Office: 938 Days
• US Class Current: 1/1
• 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; and

a hub that rotatably mates with the handle; and

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,

wherein the steering mechanism further comprises a locking mechanism controlled by at least one locking control of the plurality of controls of the handle, the locking mechanism constructed and arranged to disable one of the first and second degrees of freedom to limit a movement of the articulation region in the single plane of motion, and

wherein the locking mechanism includes a first lock that prevents the steering mechanism from articulating with the first degree of freedom and a second lock that prevents the steering mechanism from articulating with the second degree of freedom

wherein the hub includes a first post and a second post along a first articulating axis, and wherein the first lock includes a first locking ring and a first cam clamp that applies a force to the first locking ring, which prevents the housing from rotating about the first articulating axis

wherein the hub includes a third post and a fourth post along a second articulating axis orthogonal to the first articulating axis, and wherein the second lock includes a second locking ring and a second cam clamp that applies a force to the second locking ring, which prevents the housing from rotating about the second articulating axis.

2. The surgical instrument of claim 1, wherein the locking mechanism comprises two locking mechanisms controlled by the at least one locking control, and wherein the two locking mechanisms, when activated, are constructed and arranged to disable one or both of the first and second degrees of freedom to prevent steering of the articulation region.

3. The surgical instrument of claim 1, further comprising a set of first interdigitating teeth between the first locking ring and the housing, wherein the first locking ring applies a force at the first interdigitating teeth to prevent a rotation of the housing about the first articulating axis.

4. The surgical instrument of claim 3, further comprising a set of second interdigitating teeth between the second locking ring and the housing, wherein the second locking ring applies a force at the second interdigitating teeth to prevent a rotation of the handle about the second articulating axis.

5. The surgical instrument of claim 1, wherein the first articulating axis is a vertical axis, and wherein a rotation of the hub about the vertical axis provides a horizontal control of the steerable portion.

6. The surgical instrument of claim 1, wherein the second articulating axis is a horizontal axis, and wherein a rotation of the handle about the horizontal axis of the hub provides a vertical control of the articulation region.

7. The surgical instrument of claim 1, wherein an activation of either the first lock or the second lock limits movement of the articulation region to the single plane of motion.

8. The surgical instrument of claim 1, wherein an activation of both the first lock and the second lock prevents steering of the instrument, and maintains a tool at a distal end of the instrument tool in a current position.

9. The surgical instrument of claim 1, wherein the first lock and the second lock are disengaged, and the articulation region articulates in multiple planes of motion.

10. 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.

11. The surgical instrument of claim 10, 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.

12. The surgical instrument of claim 1, further comprising a plurality of steering cables coupled 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.

13. The surgical instrument of claim 12, wherein the plurality of steering cables comprise first and second steering cables that extend from the handle 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.

14. The surgical instrument of claim 13, 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.

15. The surgical instrument of claim 14, 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.

16. The surgical instrument of claim 13, wherein the hub includes first and second cable fastening locations that couple proximal ends of the first and second steering cables to the hub.

17. The surgical instrument of claim 13, further comprising 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.

18. The surgical instrument of claim 17, 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.

19. The surgical instrument of claim 18, 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.

20. The surgical instrument of claim 17, wherein the hub includes first and second cable pass-through holes and the handle includes first and second 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.

21. The surgical instrument of claim 17, wherein the handle includes a cable tensioning mechanism that adjusts a tension of the third and fourth steering cables at the proximal ends.

22. The surgical instrument of claim 21, wherein the cable tensioning mechanism comprises a set screw movably positioned in a threaded socket in the housing, 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.

23. The surgical instrument of claim 22, wherein the cable tensioning mechanism 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.

24. The surgical instrument of claim 1, further comprising a support element having a proximal end coupled to the handle, a portion of the support element extending through the articulation region, the support element constructed and arranged to rotate independently of the movement of the articulation region in the single plane of motion.

25. The surgical instrument of claim 24, wherein the support element is constructed and arranged as a coil.

26. The surgical instrument of claim 24, wherein the support element is constructed and arranged as a hollow tube.

27. The surgical instrument of claim 24, further comprising a clevis between an end effector coupled to the articulation region and a distal end of the support element.

28. 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.

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

30. The surgical instrument of claim 29, wherein the end effector includes a housing and at least one tool.

31. The surgical instrument of claim 30, wherein the at least one tool comprises at least one of:

a grasper;

a scissor;

a cutter;

a claw;

or a knife.

32. The surgical instrument of claim 30, 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.

33. The surgical instrument of claim 30, 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.