Robotically-controlled motorized surgical instrument with an end effector

• US 10,045,778 B2
• Filed: 09/23/2016
• Issued: 08/14/2018
• Est. Priority Date: 09/23/2008
• Status: Active Grant

• Current Assignee: Cilag Gmbh International (Johnson & Johnson)
• Original Assignee: Ethicon, LLC (Johnson & Johnson)
• Inventors: Yates, David C., Shelton, IV, Frederick E., Morgan, Jerome R.
• Primary Examiner(s): SZPIRA, JULIE ANN
• Application Number:
  US15/274,805
• Publication Number:
  US 20170007339A1
• Time in Patent Office: 690 Days
• CPC Class Codes: A61B 17/068 Surgical staplers , e.g. containing multiple staples or clampsstaplers containing only one staple A61B17/10; magazines or containers for staples A61B17/105; for performing anastomosis A61B17/115; staplers in general B25C5/00
• CPC Class Codes: A61B 17/07207 the staples being applied sequentially
• CPC Class Codes: A61B 2017/00075 Motion
• CPC Class Codes: A61B 2017/00314 Separate linked members
• CPC Class Codes: A61B 2017/00323 Cables or rods
• CPC Class Codes: A61B 2017/00362 Packages or dispensers for MIS instruments A61B2017/0479 takes precedence
• CPC Class Codes: A61B 2017/00398 using powered actuators, e.g. stepper motors, solenoids
• CPC Class Codes: A61B 2017/00477 Coupling A61B2017/0046 takes precedence
• CPC Class Codes: A61B 2017/00685 Archimedes screw
• CPC Class Codes: A61B 2017/00734 battery operated
• CPC Class Codes: A61B 2017/0688 Packages or dispensers for surgical staplers
• CPC Class Codes: A61B 2017/07271 characterised by its cartridge
• CPC Class Codes: A61B 2017/07278 characterised by its sled or its staple holder
• CPC Class Codes: A61B 2017/07285 characterised by its cutter
• CPC Class Codes: A61B 2017/2923 Toothed members, e.g. rack and pinion
• CPC Class Codes: A61B 2017/2927 the angular position of the head being adjustable with respect to the shaft
• CPC Class Codes: A61B 2017/2929 with a head rotatable about the longitudinal axis of the shaft
• CPC Class Codes: A61B 2017/2943 Toothed members, e.g. rack and pinion
• 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 2017/320097 : with stapling means
• CPC Class Codes: A61B 2090/065 : for measuring contact or contact pressure
• CPC Class Codes: A61B 2090/0803 : Counting the number of times an instrument is used
• CPC Class Codes: A61B 2090/0811 : for the position of a particular part of an instrument with respect to the rest of the instrument, e.g. position of the anvil of a stapling instrument
• CPC Class Codes: A61B 2090/0814 : Preventing re-use
• CPC Class Codes: A61B 34/30 : Surgical robots
• CPC Class Codes: A61B 34/70 : Manipulators specially adapted for use in surgery
• CPC Class Codes: A61B 34/71 : Manipulators operated by drive cable mechanisms
• CPC Class Codes: A61B 34/76 : Manipulators having means for providing feel, e.g. force or tactile feedback
• CPC Class Codes: A61B 50/30 : Containers specially adapted for packaging, protecting, dispensing, collecting or disposing of surgical or diagnostic appliances or instruments for wound clamps A61B17/10; for ligaturing clips A61B17/122; packages or dispensers for surgical gloves or finger-stalls A61B42/40
• CPC Class Codes: A61B 50/36 : for collecting or disposing of used articles
• CPC Class Codes: A61B 90/98 : using electromagnetic means, e.g. transponders
• CPC Class Codes: H02J 2310/23 : The load being a medical device, a medical implant, or a life supporting device
• CPC Class Codes: H02J 7/0031 : using battery or load disconnect circuits H02J9/002 takes precedence

Abstract

A surgical tool for use with a surgical system is disclosed. The surgical tool comprises a housing containing three drive motors and three non-concentric rotatable output members, a modular shaft assembly comprising three rotatable drive shafts coupled to the three non-concentric rotatable output members, an end effector comprising a first jaw and a second jaw, and a motion conversion assembly. The motion conversion assembly is operably coupled to one of the drive motors and an axial drive assembly. The motion conversion assembly is configured to convert a rotational motion of one of the three rotatable drive shafts to an axial motion. The application of the axial motion to the axial drive assembly approximates the first jaw from an open position to a closed position and performs an actuation stroke within the end effector.

Claims

1. A surgical instrument, comprising:

a housing comprising a plurality of motors;

a modular shaft assembly extending distally from the housing, wherein the modular shaft assembly is detachably coupled to the housing;

an end effector extending distally from the modular shaft assembly, the end effector comprising;

a first jaw member configured to support a removable staple cartridge; and

a second jaw member movable relative to the first jaw member between an open position and a closed position;

an axially movable drive member in operable communication with the second jaw member; and

at least three rotary drive shafts in operable communication with the plurality of motors, wherein;

a first one of the at least three rotary drive shafts is in operable engagement with the axially movable drive member, wherein at least one rotational motion of the first one of the at least three rotary drive shafts causes the axially movable drive member to move the second jaw member relative to the first jaw member from the closed position to the open position;

a second one of the at least three rotary drive shafts is coupled to a first gear assembly, wherein a rotational motion of the second one of the at least three rotary drive shafts is operable to cause an articulation of the modular shaft assembly; and

a third one of the at least three rotary drive shafts is coupled to a second gear assembly, wherein a rotational motion of the third one of the at least three rotary drive shafts is operable to cause a rotation of the end effector.

2. The surgical instrument of claim 1, wherein at least one opposite rotational motion of the first one of the at least three rotary drive shafts causes the axially movable drive member to move the second jaw member relative to the first jaw member from the open position to the closed position.

3. The surgical instrument of claim 1, wherein the second jaw member comprises a slot, and wherein the axially movable drive member comprises a camming member movable through the slot to move the second jaw member relative to the first jaw member from the closed position to the open position.

4. The surgical instrument of claim 1, wherein the axially movable drive member is configured to apply actuation forces onto the first jaw member and the second jaw member simultaneously.

5. The surgical instrument of claim 4, wherein the housing comprises a power source configured to provide power to the plurality of motors.

6. The surgical instrument of claim 5, wherein the power source comprises a battery assembly couplable to the plurality of motors.

7. The surgical instrument of claim 1, wherein the first one of the at least three rotary drive shafts is in threaded engagement with the axially movable drive member.

8. The surgical instrument of claim 1, wherein the end effector further comprises the removable staple cartridge.

9. The surgical instrument of claim 1, wherein a distal portion of the modular shaft assembly comprises a modular disposable loading unit.

10. A surgical tool for use with a robotic system, the surgical tool comprising:

a housing couplable to the robotic system, wherein the housing covers at least two drive motors and three non-concentric rotatable body members;

a modular shaft assembly detachably coupled to the housing, wherein the modular shaft assembly comprises three rotary drive shafts coupled to the three non-concentric rotatable body members, wherein at least two of the rotary drive shafts are concentric with one another;

an end effector extending distally from the modular shaft assembly, the end effector comprising;

a first jaw member configured to support a removable staple cartridge; and

a second jaw member movable relative to the first jaw member;

and

a motion conversion assembly positioned at least partially within the modular shaft assembly, wherein the motion conversion assembly is operably coupled to one of the at least two drive motors and an axial drive assembly, wherein the motion conversion assembly is configured to convert a rotational motion of one of the three rotary drive shafts to an axial motion, wherein application of the axial motion to the axial drive assembly causes approximation of the first and second jaw members from an open position to a closed position and advancement of a firing member within the end effector.

11. The surgical tool of claim 10, wherein the second jaw member is movable relative to the first jaw member from the closed position to the open position in response to an opposite axial motion, and wherein the motion conversion assembly is configured to convert an opposite rotational motion of the one of the three rotary drive shafts to the opposite axial motion.

12. The surgical tool of claim 10, wherein the motion conversion assembly comprises:

an actuation member in operable communication with the second jaw member; and

a rotary input in operable communication with the one of the at least two drive motors, wherein the rotary input is configured to receive the rotational motion of the one of the three rotary drive shafts, and wherein the actuation member is configured to transmit the axial motion to the second jaw member.

13. The surgical tool of claim 12, wherein the actuation member is in threaded engagement with the rotary input.

14. The surgical tool of claim 10 further comprising a power source configured to provide power for the at least two drive motors.

15. The surgical tool of claim 10, wherein the end effector further comprises the removable staple cartridge.

16. The surgical tool of claim 10, wherein the modular shaft assembly comprises a modular disposable loading unit.

17. A surgical tool for use with a robotic system, the surgical tool comprising:

a housing couplable to the robotic system;

a modular shaft assembly detachably coupled to the housing;

an end effector extending distally from the modular shaft assembly, the end effector comprising;

a first jaw member configured to support a removable staple cartridge; and

a second jaw member movable relative to the first jaw member from an open position to a closed position;

a plurality of drive motors;

a battery assembly coupled to the plurality of drive motors;

camming means for camming the second jaw member relative to the first jaw member from the open position to the closed position;

rotary input means for driving the camming means; and

firing means distinct and independent from the camming means.

18. A surgical instrument, comprising:

a housing comprising a plurality of motors;

a modular shaft assembly extending distally from the housing, wherein the modular shaft assembly is detachably coupled to the housing;

an end effector extending distally from the modular shaft assembly, wherein the end effector comprises a first jaw and a second jaw;

a longitudinally movable drive member;

a first rotatable drive shaft in operable communication with one of the motors and in operable engagement with the longitudinally movable drive member, wherein rotational motion of the first rotatable drive shaft causes the longitudinally movable drive member to move the first jaw relative to the second jaw;

a second rotatable drive shaft in operable communication with one of the motors and coupled to a first gear assembly, wherein rotational motion of the second rotatable drive shaft articulates the end effector; and

a third rotatable drive shaft in operable communication with one of the motors and coupled to a second gear assembly, wherein rotational motion of the third rotatable drive shaft rotates the end effector.

19. A surgical tool for use with a surgical system, the surgical tool comprising:

a housing couplable to the surgical system, wherein the housing contains three drive motors and three non-concentric rotatable output members;

a modular shaft assembly detachably coupled to the housing, wherein the modular shaft assembly comprises three rotatable drive shafts coupled to the three non-concentric rotatable output members, wherein at least two of the rotatable drive shafts are concentric with one another;

an end effector extending distally from the modular shaft assembly, wherein the end effector comprises a first jaw and a second jaw; and

a motion conversion assembly positioned within the modular shaft assembly, wherein the motion conversion assembly is operably coupled to one of the drive motors and an axial drive assembly, wherein the motion conversion assembly is configured to convert a rotational motion of one of the three rotatable drive shafts to an axial motion, wherein the application of the axial motion to the axial drive assembly approximates the first jaw from an open position to a closed position and performs an actuation stroke within the end effector.

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

a housing couplable to the surgical system;

a modular shaft assembly detachably coupled to the housing;

an end effector extending distally from the modular shaft assembly, wherein the end effector comprises a first jaw and a second jaw;

a plurality of drive motors;

a battery assembly configured to power the plurality of drive motors;

camming means for camming the first jaw relative to the second jaw;

rotary input means for driving the camming means; and

firing means distinct and independent from the camming means.