Robotic surgical devices, systems, and related methods

• US 10,667,883 B2
• Filed: 03/14/2014
• Issued: 06/02/2020
• Est. Priority Date: 03/15/2013
• Status: Active Grant

• Current Assignee: Virtual Incision Corporation
• Original Assignee: Virtual Incision Corporation
• Inventors: Farritor, Shane, Santoro, Chris, Shasho, Jeff, Kumar, Nishant, Szczesiak, Mateusz, Herman, Jason
• Primary Examiner(s): Layno, Carl H
• Assistant Examiner(s): Xie, Dacheng
• Application Number:
  US14/212,686
• Publication Number:
  US 20140303434A1
• Time in Patent Office: 2,272 Days
• CPC Class Codes: A61B 1/00149 using articulated arms
• CPC Class Codes: A61B 1/3132 for laparoscopy
• CPC Class Codes: A61B 17/29 Forceps for use in minimally invasive surgery
• CPC Class Codes: A61B 17/3423 Access ports, e.g. toroid shape introducers for instruments or hands access sites for liquids A61M39/0247
• CPC Class Codes: A61B 2034/302 specifically adapted for manipulations within body cavities, e.g. within abdominal or thoracic cavities
• CPC Class Codes: A61B 2034/305 Details of wrist mechanisms at distal ends of robotic arms
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: A61B 46/10 specially adapted for instruments, e.g. microscopes
• CPC Class Codes: A61B 90/30 Devices for illuminating a surgical field, the devices having an interrelation with other surgical devices or with a surgical procedure
• CPC Class Codes: A61B 90/35 Supports therefor
• CPC Class Codes: A61B 90/361 Image-producing devices, e.g. surgical cameras
• CPC Class Codes: A61B 90/50 Supports for surgical instruments, e.g. articulated arms

Abstract

The embodiments disclosed herein relate to various medical device components, including components that can be incorporated into robotic and/or in vivo medical devices. Certain embodiments include various modular medical devices for in vivo medical procedures.

Claims

1. A surgical robotic system for performing surgery on a patient, comprising:

a. a robotic device sized to be positioned into a cavity of the patient by way of a port positioned in an incision of a patient, the device comprising;

i. a unitary elongate device body;

ii. a first shoulder joint movably coupled to a distal end of the device body;

iii. a second shoulder joint movably coupled to the distal end of the device body;

iv. a first movable segmented robotic arm operationally connected to the first shoulder joint and comprising;

A. a first upper arm segment comprising a housing enclosing a plurality of first upper arm actuators;

B. a first lower arm segment comprising a housing enclosing at least one first lower arm actuator;

C. a plurality of first arm motor gears and driven gears constructed and arranged to translate movement from the first arm actuators to movement of the first movable segmented robotic arm; and

D. a first operational component; and

v. a second movable segmented robotic arm operationally connected to the second shoulder joint and comprising;

A. a second upper arm segment comprising a housing enclosing a plurality of second upper arm actuators;

B. a second lower arm segment comprising a housing enclosing at least one second lower arm actuator; and

C. a plurality of second arm motor gears and driven gears constructed and arranged to translate movement from the second arm actuators to movement of the second movable segmented robotic arm; and

D. a second operational component; and

b. a console in electrical communication with the robotic device, the console configured to control the robotic device from outside the patient,

wherein;

a. the unitary device body is configured to be inserted into the port such that the distal end is within the cavity and at least a portion of the device body is external to the cavity,

b. the first and second moveable segmented arms are capable of being positioned substantially parallel with a longitudinal axis of the device body for insertion by way of the port, and

c. the first and second lower arm lower arm actuators are constructed and arranged to tool roll and tool drive the first and second operational components.

2. The surgical robotic system of claim 1, wherein the robotic device comprises at least one actuator for operation, rotation or movement of at least one of the first shoulder, the second shoulder, the first segmented arm, the second segmented arm, the first operational component, and the second operational component.

3. The surgical robotic system of claim 2, wherein the at least one actuator is a brushless DC motor.

4. The surgical robotic system of claim 3, wherein the device body further comprises a rigid-flex PCB in operational communication with the actuator and configured to perform yaw and pitch functions.

5. The surgical robotic system of claim 1, wherein the first movable segmented robotic arm further comprises:

a. a first upper arm segment;

b. a first elbow joint; and

c. a first lower arm segment,

wherein the first upper arm segment is configured to be capable of roll, pitch and yaw relative to the first shoulder joint and the first lower arm is configured to be capable of yaw relative to the first upper arm by way of the elbow joint.

6. The surgical robotic system of claim 5, wherein the first operational component is chosen from a group consisting of a grasping component, a cauterizing component, a suturing component, an imaging component, an irrigation component, a suction component, an operational arm component, a sensor component, and a lighting component.

7. The surgical robotic system of claim 5, wherein the second operational component is chosen from a group consisting of a grasping component, a cauterizing component, a suturing component, an imaging component, an irrigation component, a suction component, an operational arm component, a sensor component, and a lighting component.

8. A surgical robotic system for performing minimally-invasive surgery on a patient, comprising:

a. a robotic device sized to be positioned into a patient body cavity, the device comprising;

i. an elongate device body constructed and sized to be positioned through an incision and into the body cavity of the patient;

ii. a first shoulder joint movably coupled to a distal end of the device body;

iii. a second shoulder joint movably coupled to the distal end of the device body;

iv. a first movable segmented robotic arm operationally connected to the first shoulder joint and comprising;

A. a first upper arm segment comprising a housing enclosing a plurality of first upper arm actuators;

B. a first lower arm segment comprising a housing enclosing at least one first lower arm actuator;

C. a plurality of first arm motor gears and driven gears constructed and arranged to translate movement from the first arm actuators to movement of the first movable segmented robotic arm; and

D. a first operational component; and

v. a second movable segmented robotic arm operationally connected to the second shoulder joint and comprising;

A. a second upper arm segment comprising a housing enclosing a plurality of second upper arm actuators;

B. a second lower arm segment comprising a housing enclosing at least one second lower arm actuator; and

C. a plurality of second arm motor gears and driven gears constructed and arranged to translate movement from the second arm actuators to movement of the second movable segmented robotic arm; and

D. a second operational component; and

b. a console for control of the robotic device from outside the patient by way of a port positioned in the incision, the console in electrical communication with the robotic device.

9. The surgical robotic system of claim 8, wherein:

a. the first lower robotic arm segment comprises a first elbow joint,

b. the second lower robotic arm segment comprises a second elbow joint,

c. the first lower arm and second lower arm are configured to be capable of yaw relative to the upper arm by way of the first and second elbow joints, and

d. the first and second moveable segmented arms are capable of being positioned substantially parallel with a longitudinal axis of the device body for insertion by way of the port.

10. The surgical robotic system of claim 9, wherein at least one actuator is configured for rotation or movement of at least one of the first shoulder joint, the second shoulder joint, the first upper robotic arm segment, the second upper robotic arm segment, the first lower robotic arm segment, the second lower robotic arm segment, the first operational component, and the second operational component.

11. The surgical robotic system of claim 9, wherein the first operational component is chosen from a group consisting of a grasping component, a cauterizing component, a suturing component, an imaging component, an irrigation component, a suction component, an operational arm component, a sensor component, and a lighting component.

12. The surgical robotic system of claim 9, wherein the second operational component is chosen from a group consisting of a grasping component, a cauterizing component, a suturing component, an imaging component, an irrigation component, a suction component, an operational arm component, a sensor component, and a lighting component.

13. A minimally invasive surgery system, comprising:

a. a robotic device comprising;

i. an elongate device body having proximal and distal ends and being constructed and sized to be positioned through an incision and into the body cavity of the patient;

ii. a first movable segmented robotic arm operationally connected to the first shoulder joint and comprising;

A. a first shoulder joint movably coupled to a distal end of the device body;

B. a first upper arm segment comprising a housing enclosing a plurality of first upper arm actuators;

C. a first elbow joint;

D. a first lower arm segment comprising a housing enclosing at least one first lower arm actuator;

E. a plurality of first arm motor gears and driven gears constructed and arranged to translate movement from the first arm upper and lower actuators to movement of the first movable segmented robotic arm; and

F. a first operational component; and

iii. a second movable segmented robotic arm operationally connected to the second shoulder joint and comprising;

A. a second shoulder joint movably coupled to the distal end of the device body;

B. a second upper arm segment comprising a housing enclosing a plurality of second upper arm actuators;

C. a second elbow joint;

D. a second lower arm segment comprising a housing enclosing at least one second lower arm actuator; and

E. a plurality of second arm motor gears and driven gears constructed and arranged to translate movement from the second arm upper and lower actuators to movement of the second movable segmented robotic arm; and

F. a second operational component;

wherein the robotic device is constructed and arranged for insertion and operation via;

a. positioning the first and second moveable segmented arms substantially in line with a longitudinal axis of the device body prior to insertion into a body cavity of a patient,

b. inserting the distal end of the robotic device into the body cavity of the patient through a port in communication with the body cavity such that the first and second movable segmented robotic arms are disposed entirely within the body cavity and the elongate device body is disposed in the port such that the distal end of the device body is disposed within the body cavity and the proximal end of the device body is disposed outside the body cavity, and

c. rotating the first and second moveable segmented arms such that the first and second elbow joints project outward from the longitudinal axis.

14. The system of claim 13, wherein the device is constructed and arranged to be rotated and/or tilted inside the patient relative to the initial insert position.

15. The system of claim 13, wherein the first and second moveable segmented arms are constructed and arranged for performing yaw and pitch functions.

16. The system of claim 13, wherein the device body further comprises a first rigid-flex PCB in operational communication with the first movable segmented robotic arm and a second rigid-flex PCB in operational communication with the second movable segmented robotic arm.

17. The surgical robotic system of claim 13, wherein the first and second upper arm segments are constructed and arranged to be capable of roll, pitch and yaw relative to the first and second shoulder joints, respectively, and the first and second lower arm segments are configured to be capable of yaw relative to the first and second upper arm segments by way of the first and second elbow joints, respectively.

18. The surgical robotic system of claim 13, further comprising at least one absolute position sensor comprising a magnetic encoder.