Robotic surgical devices, systems, and related methods

• US 10,806,538 B2
• Filed: 08/03/2016
• Issued: 10/20/2020
• Est. Priority Date: 08/03/2015
• Status: Active Grant

• Current Assignee: Virtual Incision Corporation
• Original Assignee: Virtual Incision Corporation
• Inventors: Farritor, Shane, Shasho, Jeff, Kumar, Nishant, Szczesiak, Mateusz, Herman, Jason, Santoro, Chris
• Primary Examiner(s): Kasztejna, Matthew J
• Application Number:
  US15/227,813
• Publication Number:
  US 20170035526A1
• Time in Patent Office: 1,539 Days
• Field of Search: 600101, 600104, 600107, 600112, 600114, 600121-125, 600170-173, 600176, 606 32- 58
• CPC Class Codes: A61B 1/00128 mechanical, e.g. for tubes or pipes
• CPC Class Codes: A61B 1/00135 Oversleeves mounted on the endoscope prior to insertion
• CPC Class Codes: A61B 1/00137 End pieces at either end of the endoscope, e.g. caps, seals or forceps plugs
• CPC Class Codes: A61B 1/00154 using guiding arrangements for insertion
• CPC Class Codes: A61B 1/0051 with controlled bending of insertion part
• CPC Class Codes: A61B 2034/2048 using an accelerometer or inertia sensor
• CPC Class Codes: A61B 2034/2059 Mechanical position encoders
• CPC Class Codes: A61B 2034/252 indicating steps of a surgical procedure
• CPC Class Codes: A61B 2034/301 for introducing or steering flexible instruments inserted into the body, e.g. catheters or endoscopes
• CPC Class Codes: A61B 2034/302 specifically adapted for manipulations within body cavities, e.g. within abdominal or thoracic cavities
• CPC Class Codes: A61B 2034/303 specifically adapted for manipulations within body lumens, e.g. within lumen of gut, spine, or blood vessels
• CPC Class Codes: A61B 2034/305 Details of wrist mechanisms at distal ends of robotic arms
• CPC Class Codes: A61B 2090/306 using optical fibres
• CPC Class Codes: A61B 34/30 Surgical robots
• CPC Class Codes: A61B 34/35 for telesurgery
• CPC Class Codes: A61B 34/76 Manipulators having means for providing feel, e.g. force or tactile feedback
• CPC Class Codes: A61B 90/361 Image-producing devices, e.g. surgical cameras

Abstract

The various inventions relate to robotic surgical devices, consoles for operating such surgical devices, operating theaters in which the various devices can be used, insertion systems for inserting and using the surgical devices, and related methods.

Claims

1. A robotic surgical system, comprising:

a robotic surgical device comprising;

an elongate device body having proximal and distal ends and comprising;

a camera lumen defined within the device body, the camera lumen comprising;

a proximal lumen opening;

a socket defined distally of the proximal lumen opening, the socket comprising a first diameter and a first coupling component;

an extended portion defined distally of the socket, the extended portion having a second, smaller diameter; and

a distal lumen opening in the distal end of the device body, the distal lumen opening defined at a distal end of the extended portion;

a seal structure defined distally of the socket and proximally of the extended portion, the seal structure comprising a ring seal and a one-way seal;

first and second shoulder joints operably coupled to the distal end of the device body;

a first segmented robotic arm operably coupled to the first shoulder joint; and

a second segmented robotic arm operably coupled to the second shoulder joint; and

a camera component, comprising;

a handle comprising;

a distal end configured to be positionable within the socket;

a second coupling component configured to releasably couple with the first coupling component, thereby releasably locking the handle into the socket; and

at least one actuator disposed within the handle; and

an elongate tube operably coupled to the handle, wherein the elongate tube is configured and sized to be positionable through the camera lumen, the elongate tube comprising;

a rigid section defining a lumen;

an optical section; and

a flexible section operably coupling the optical section to the rigid section;

wherein the elongate tube has a length such that at least the optical section is configured to extend distally from the distal lumen opening when the camera component is positioned through the camera lumen, and the at least one actuator disposed within the handle is constructed and arranged to perform camera component pan and camera component tilt.

2. The robotic surgical system of claim 1, wherein the seal structure comprises a ring-seal retention component, wherein the ring seal is retained within the ring-seal retention component.

3. The robotic surgical system of claim 2, wherein the ring-seal retention component comprises at least one protrusion extending from an outer wall of the ring-seal retention component.

4. The robotic surgical system of claim 3, wherein the socket further comprises a channel defined in an inner wall of the socket, wherein the channel is configured to receive the at least one protrusion.

5. The robotic surgical system of claim 1, wherein the handle comprises a controller configured to operate the camera component.

6. The robotic surgical system of claim 1, wherein the distal lumen opening is positioned between the first and second shoulder joints.

7. The robotic surgical system of claim 1, wherein the optical section is configured to be tiltable at the flexible section in relation to the rigid section, wherein the optical section has a straight configuration and a tilted configuration.

8. The robotic surgical system of claim 1, wherein the elongate tube is configured to be rotatable in relation to the handle.

9. The robotic surgical system of claim 1, wherein the socket further comprises an inner wall comprising a channel configured to receive an insertion device.

10. A robotic surgical system, comprising:

(a) a robotic surgical device comprising;

(i) a device body comprising;

(A) a distal end;

(B) a proximal end; and

(C) a camera lumen defined within the device body, the camera lumen comprising;

(1) a socket defined in the camera lumen, the socket comprising a first coupling component; and

(2) a seal structure defined distally of the socket, wherein the seal structure comprises a ring seal and a one-way seal;

(ii) first and second shoulder joints operably coupled to the distal end of the device body;

(iii) a first robotic arm operably coupled to the first shoulder joint; and

(iv) a second robotic arm operably coupled to the second shoulder joint;

(b) a camera component, comprising;

(i) a handle comprising;

(A) a distal end configured to be positionable within the socket;

(B) a second coupling component configured to releasably couple with the first coupling component, thereby releasably locking the handle into the socket; and

(C) at least one actuator disposed within the handle; and

(ii) an elongate tube operably coupled to the handle, wherein the elongate tube is configured and sized to be positionable through the camera lumen, the elongate tube comprising;

(A) a rigid section;

(B) an optical section; and

(C) a flexible section operably coupling the optical section to the rigid section,

wherein the elongate tube has a length such that at least the optical section is configured to extend distally from a distal lumen opening of the camera lumen when the camera component is positioned through the camera lumen, and

the at least one actuator disposed within the handle is constructed and arranged to perform camera component pan and camera component tilt.

11. The robotic surgical system of claim 10, wherein the first robotic arm further comprises:

(a) a first arm upper arm;

(b) a first arm elbow joint; and

(c) a first arm lower arm,

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

12. The surgical robotic system of claim 11, wherein the first robotic arm further comprises at least one first arm actuator disposed within the first robotic arm.

13. The robotic surgical system of claim 11, wherein the second robotic arm further comprises:

(a) a second arm upper arm;

(b) a second arm elbow joint; and

(c) a second arm lower arm,

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

14. The surgical robotic system of claim 13, wherein the second robotic arm further comprises at least one second arm actuator disposed within the second robotic arm.

15. The robotic surgical system of claim 10, wherein the first shoulder joint comprises a first rotatable housing rotatably coupled to the distal end of the device body and the second shoulder joint comprises a second rotatable housing rotatably coupled to the distal end of the device body.

16. A robotic surgical system comprising:

(a) a robotic surgical device comprising;

(i) an elongate device body having proximal and distal ends and comprising a camera lumen defined within the device body, the camera lumen comprising;

(A) a proximal lumen opening;

(B) a socket defined distally of the proximal lumen opening, the socket comprising a first diameter and a first coupling component;

(C) an extended section defined distally of the socket, the extended section having a second, smaller diameter; and

(D) a distal lumen opening in the distal end of the device body, the distal lumen opening defined at a distal end of the extended section;

(ii) first and second shoulder joints operably coupled to the distal end of the device body, the first shoulder joint comprising a first rotatable housing rotatably coupled to the distal end of the device body and the second shoulder joint comprising a second rotatable housing rotatably coupled to the distal end of the device body;

(iii) a first segmented robotic arm operably coupled to the first shoulder joint; and

(iv) a second segmented robotic arm operably coupled to the second shoulder joint; and

(v) a first drivetrain comprising;

(A) a first body actuator disposed within the device body; and

(B) a first transmission shaft operably coupled to the first body actuator, wherein the first transmission shaft is operably coupled to the first rotatable housing;

(vi) a second drivetrain comprising;

(A) a second body actuator disposed within the device body; and

(B) a second transmission shaft operably coupled to the second body actuator, wherein the second transmission shaft is operably coupled to a first shoulder link;

(vii) a third drivetrain comprising;

(A) a third body actuator disposed within the device body; and

(B) a third transmission shaft operably coupled to the third body actuator, wherein the third transmission shaft is operably coupled to the second rotatable housing; and

(viii) a fourth drivetrain comprising;

(A) a fourth body actuator disposed within the device body; and

(B) a fourth transmission shaft operably coupled to the fourth body actuator, wherein the fourth transmission shaft is operably coupled to a second shoulder link;

(b) a camera component, comprising;

(i) a handle comprising;

(A) a distal end configured to be positionable within the socket;

(B) a second coupling component configured to releasably couple with the first coupling component, thereby releasably locking the handle into the socket; and

(C) at least one actuator disposed within the handle; and

(ii) an elongate tube operably coupled to the handle, wherein the elongate tube is configured and sized to be positionable through the camera lumen, the elongate tube comprising;

(A) a rigid section defining a lumen;

(B) an optical section; and

(C) a flexible section operably coupling the optical section to the rigid section;

wherein the elongate tube has a length such that at least the optical section is configured to extend distally from the distal lumen opening when the camera component is positioned through the camera lumen, and the at least one actuator disposed within the handle is constructed and arranged to perform camera component pan and camera component tilt.

17. A robotic surgical system, comprising:

(a) a robotic surgical device comprising;

(i) a device body comprising;

(A) a distal end;

(B) a proximal end; and

(C) a camera lumen defined within the device body, the camera lumen comprising a socket defined in the camera lumen, the socket comprising a first coupling component;

(ii) first and second shoulder joints operably coupled to the distal end of the device body;

(iii) a first robotic arm operably coupled to the first shoulder joint; and

(iv) a second robotic arm operably coupled to the second shoulder joint;

(v) a first drivetrain comprising;

(A) a first body actuator disposed within the device body; and

(B) a first transmission shaft operably coupled to the first body actuator, wherein the first transmission shaft is operably coupled to the first rotatable housing;

(vi) a second drivetrain comprising;

(A) a second body actuator disposed within the device body; and

(B) a second transmission shaft operably coupled to the second body actuator, wherein the second transmission shaft is operably coupled to a first shoulder link;

(vii) a third drivetrain comprising;

(A) a third body actuator disposed within the device body; and

(B) a third transmission shaft operably coupled to the third body actuator, wherein the third transmission shaft is operably coupled to the second rotatable housing; and

(viii) a fourth drivetrain comprising;

(A) a fourth body actuator disposed within the device body; and

(B) a fourth transmission shaft operably coupled to the fourth body actuator, wherein the fourth transmission shaft is operably coupled to a second shoulder link;

(b) a camera component, comprising;

(i) a handle comprising;

(A) a distal end configured to be positionable within the socket;

(B) a second coupling component configured to releasably couple with the first coupling component, thereby releasably locking the handle into the socket portion; and

(C) at least one actuator disposed within the handle; and

(ii) an elongate tube operably coupled to the handle, wherein the elongate tube is configured and sized to be positionable through the camera lumen, the elongate tube comprising;

(A) a rigid section;

(B) an optical section; and

(C) a flexible section operably coupling the optical section to the rigid section,

wherein the elongate tube has a length such that at least the optical section is configured to extend distally from a distal lumen opening of the camera lumen when the camera component is positioned through the camera lumen, and

the at least one actuator disposed within the handle is constructed and arranged to perform camera component pan and camera component tilt.