SURGICAL INSTRUMENTS, RELATED SYSTEMS, AND RELATED METHODS
20220395313 · 2022-12-15
Assignee
Inventors
- Lawrence KERVER (San Jose, CA, US)
- Harsukh RATIA (Foster City, CA, US)
- Craig GERBI (Half Moon Bay, CA, US)
Cpc classification
A61B2018/0091
HUMAN NECESSITIES
A61B2034/305
HUMAN NECESSITIES
A61B18/1482
HUMAN NECESSITIES
A61B18/1442
HUMAN NECESSITIES
International classification
Abstract
A method of assembling a surgical instrument comprising an end effector body and a retaining member includes inserting a distal end feature of a cable within a recess in the end effector body, the distal end feature extending radially outwardly from the cable. The method further includes positioning a retaining member over the recess in the end effector body to retain the distal end feature of the cable within the retaining member.
Claims
1.-3. (canceled)
4. A method of assembling a surgical instrument, the surgical instrument comprising an end effector and a retaining member, the method comprising: inserting a distal end feature of a cable within a recess in an end effector proximal body portion, the distal end feature extending radially outwardly from the cable; positioning a retaining member over the recess of the end effector proximal body portion to retain the distal end feature of the cable within the retaining member and in abutment with a first shoulder of the end effector proximal body portion and a second shoulder of the retaining member.
5. The method of claim 4, wherein a proximal surface of the distal end feature of the cable is in abutment with a distal-facing surface of each of the first shoulder of the end effector proximal body portion and the second shoulder of the retaining member.
6. The method of claim 4, wherein the cable is routed through a shaft of a surgical instrument and mechanical interference between the distal end feature of the cable and the first shoulder of the end effector proximal body portion and the second shoulder of the retaining member retains the end effector proximal body portion in a coupled state with the shaft.
7. The method of claim 4, wherein the end effector proximal body portion is made from a first material with a first yield strength, and wherein the retaining member is made from a second material with a second yield strength higher than the first yield strength.
8. The method of claim 7, wherein the end effector proximal body portion is made from a polymer material, and wherein the retaining member is made from a metallic material.
9. The method of claim 4, further comprising: molding the end effector body proximal portion around a distal end tool component of the end effector.
10. An end effector assembly for an instrument, the end effector assembly comprising: an end effector comprising a distal end tool component and a proximal body portion having a first distal-facing surface; a retaining member configured to receive the proximal body portion of the end effector and couple the end effector to a shaft of an instrument, the retaining member comprising a second distal-facing surface; an actuation cable having a longitudinal axis and a distal end feature attached at a distal end portion of the actuation cable, the distal end feature comprising a proximal-facing surface, wherein the proximal-facing surface of the distal end feature of the actuation cable abuts the first distal-facing surface of the proximal body portion of the end effector and the second distal-facing surface of the retaining member.
11. The end effector assembly of claim 10, wherein the actuation cable is configured to control articulation of end effector.
12. The end effector assembly of claim 10, wherein the proximal body portion of the end effector comprises a shoulder, the first distal-facing surface being on the shoulder.
13. The end effector assembly of claim 12, wherein the proximal body portion of the end effector comprises a recess at least partially defined by the shoulder and configured to receive the distal end feature of the actuation cable.
14. The end effector assembly of claim 10, wherein the retaining member comprises an annular portion configured to circumferentially surround the proximal body portion of the end effector.
15. The end effector assembly of claim 10, wherein the distal end feature of the actuation cable comprises a barrel-shaped structure crimped to the actuation cable.
16. The end effector assembly of claim 10, wherein the first distal-facing surface and the second distal-facing surface are aligned along the longitudinal axis of the actuation cable.
17. The end effector assembly of claim 10, wherein mechanical interference between the proximal-facing surface of the distal end feature of the actuation cable and the first distal-facing surface and the second-distal facing surface is configured to retain the end effector assembly in a coupled state with the instrument shaft.
18. The end effector assembly of claim 10, wherein the proximal body portion of the end effector is made from a first material with a first yield strength, and wherein the retaining member is made from a second material with a second yield strength higher than the first yield strength.
19. The end effector assembly of claim 18, wherein the proximal body portion of the end effector is made from a polymer material, and wherein the retaining member is made from a metallic material.
20. The end effector assembly of claim 10, wherein the distal end tool component of the end effector is configured to deliver electrosurgical energy.
21. The end effector assembly of claim 10, wherein the actuation cable is a first actuation cable and the end effector assembly further comprises a second actuation cable, and wherein the second actuation cable comprising a second enlarged end feature comprises a second proximal-facing surface abutting a third distal-facing surface of the end effector body and a fourth distal-facing surface of the retaining member.
22. The end effector assembly of claim 21, wherein the proximal body portion of the end effector comprises a first recess at least partly defined by the first distal-facing surface and a second recess at least partly defined by a third distal-facing surface, and wherein the first enlarged end feature is at least partially received in the first recess and the second enlarged end feature is at least partially received in the second recess.
23. The end effector assembly of claim 22, wherein the proximal body portion of the end effector comprises a first aperture adjoining the first recess and a second aperture adjoining the second recess, and wherein the first actuation cable extends through the first aperture and the second actuation cable extends through the second aperture.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0009] The present disclosure can be understood from the following detailed description, either alone or together with the accompanying drawings. The drawings are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification. The drawings illustrate one or more exemplary embodiments of the present teachings and together with the description serve to explain certain principles and operation. In the drawings,
[0010]
[0011]
[0012]
[0013]
[0014]
[0015]
DETAILED DESCRIPTION
[0016] In exemplary embodiments of the present disclosure, a surgical instrument includes various components coupled to one another through interaction with an enlarged distal end of a cable of the surgical instrument. For example, in an exemplary embodiment, a proximal face of the enlarged distal end of the cable abuts a portion of an end effector body to retain the end effector to a distal surface of a component of the surgical instrument, such as a distal surface of an articulatable joint of the surgical instrument. In some exemplary embodiments, the end effector body includes a recess configured to receive the enlarged distal end of the cable. A shoulder of the end effector body partially defines the recess, and at least a first portion of the proximal face of the enlarged distal end of the cable abuts the shoulder of the end effector body.
[0017] In exemplary embodiments, the surgical instrument includes a retaining member configured to retain the enlarged distal end of the cable within the recess of the end effector body. For example, the retaining member surrounds at least a portion of the end effector body including the one or more recesses. In an assembled position with the end effector body and the cable of the surgical instrument, the retaining member holds the enlarged end of the cable in place within the recess of the end effector body. In some exemplary embodiments, the retaining member includes a shoulder which, in the assembled position of the retaining member with the end effector body and cable of the surgical instrument, abuts a second portion of the proximal face of the enlarged end of the cable. Tension applied to the cable is transferred through the shoulders of the end effector body and the retaining member and holds the end effector body and retaining member axially against a distal surface of a component of the surgical instrument, such as a distal surface of an articulatable joint coupled with a shaft of the surgical instrument.
[0018] In some exemplary embodiments, the enlarged end of the cable is a barrel end. The barrel end is attached to the cable by crimping, soldering, welding, mechanical interference between the barrel end and the cable (e.g., an interference fit), or other methods. In some exemplary embodiments, the body of the end effector is made from an electrically insulating material, such as a polymer. In exemplary embodiments, the retaining member is configured to provide lateral support to the end effector body. In some exemplary embodiments, the retaining member is made from a material exhibiting greater mechanical strength (e.g., yield strength) than a material of the end effector body. For example, in an exemplary embodiment, the end effector body is made from a polymer, while the retaining member is made from a metal or metal alloy, such as stainless steel.
[0019] Exemplary embodiments described herein can be used, for example, with teleoperated, computer-assisted surgical systems (sometimes referred to as robotic surgical systems) such as those described in, for example, U.S. Patent App. Pub. No. US 2013/0325033 A1 (published Dec. 5, 2013), entitled “Multi-Port Surgical Robotic System Architecture,” U.S. Patent App. Pub. No. US 2013/0325031 A1 (published Dec. 5, 2013), entitled “Redundant Axis and Degree of Freedom for Hardware-Constrained Remote Center Robotic Manipulator,” and U.S. Pat. No. 8,852,208 (issued Oct. 7, 2014), entitled “Surgical System Instrument Mounting,” and U.S. Pat. No. 8,545,515 (issued Oct. 1, 2013), entitled Curved Cannula Surgical System, each of which is hereby incorporated by reference in its entirety. Further, the exemplary embodiments described herein may be used, for example, with a da Vinci® Surgical System, such as the da Vinci Si® Surgical System or the da Vinci Xi® Surgical System, both with or without Single-Site® single orifice surgery technology, all commercialized by Intuitive Surgical, Inc. Although the above references discuss surgical instruments and other devices related to a patient side cart of a teleoperated surgical system, the present disclosure is not limited to use with surgical instruments for a teleoperated surgical system. For example, various exemplary embodiments described herein can optionally be used in conjunction with hand-held, manual surgical instruments, such as laparoscopic instruments.
[0020] Referring now to
[0021] In the exemplary embodiment of
[0022] In the exemplary embodiment of
[0023] Partly visible in
[0024] As shown in
[0025] Referring now to
[0026] As also shown in
[0027] Referring now to
[0028] Shown in
[0029] Referring now to
[0030] In exemplary embodiments, the retaining member 120 includes features configured to retain the enlarged ends 124 of the cables 116 within the recesses 126 of the end effector body portion 118. For example, as shown in
[0031] Referring now to
[0032] The assembly of the cautery hook 112, the insulating member 113, and electrically conductive conduit 114 are placed in a mold, and the end effector body portion 118 is molded (e.g., by injection molding) around the cautery hook 112 and insulating member 113. In an exemplary embodiment, the end effector body portion 118 is made from a polymer such as polyphthalamide, or other polymers, such as those noted by example above. The cautery hook 112 and the insulating member 113 include various features configured to interface with the material of the end effector body portion 118 to retain the cautery hook, insulating member 113, and end effector body portion together. For example, the insulating member 113 includes an annular recess 150 (also shown in
[0033] Following molding of the end effector body portion 118 around the cautery hook 112 and insulating member 113, assembly of the surgical instrument 100 is continued by threading each of cables 116 through respective holes 146 (
[0034] Surgical instruments of the disclosure may exhibit various advantages over other configurations of surgical instruments. For example, in some conventional designs, various portions of the surgical instrument are coupled by laser-welding processes. Such processes typically require expensive tooling, and once welded, the surgical instrument cannot be disassembled. Surgical instruments of the present disclosure potentially require less tooling and equipment for manufacture. In addition, surgical instruments of the present disclosure can be disassembled by reversing the steps of assembly, thereby facilitating replacement of the end effector components, the articulatable joint, the shaft 104, etc. Further, because the enlarged ends of the cables are contained within the retaining member, if the enlarged ends or cables fail during use (e.g., during a surgical operation in which the end effector is located at a surgical site), the failed component would remain contained within the end effector assembly.
[0035] This description and the accompanying drawings that illustrate exemplary embodiments should not be taken as limiting. Various mechanical, compositional, structural, electrical, and operational changes may be made without departing from the scope of this description and the invention as claimed, including equivalents. In some instances, well-known structures and techniques have not been shown or described in detail so as not to obscure the disclosure. Like numbers in two or more figures represent the same or similar elements. Furthermore, elements and their associated features that are described in detail with reference to one embodiment may, whenever practical, be included in other embodiments in which they are not specifically shown or described. For example, if an element is described in detail with reference to one embodiment and is not described with reference to a second embodiment, the element may nevertheless be claimed as included in the second embodiment.
[0036] For the purposes of this specification and appended claims, unless otherwise indicated, all numbers expressing quantities, percentages, or proportions, and other numerical values used in the specification and claims, are to be understood as being modified in all instances by the term “about,” to the extent they are not already so modified. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.
[0037] It is noted that, as used in this specification and the appended claims, the singular forms “a,” “an,” and “the,” and any singular use of any word, include plural referents unless expressly and unequivocally limited to one referent. As used herein, the term “include” and its grammatical variants are intended to be non-limiting, such that recitation of items in a list is not to the exclusion of other like items that can be substituted or added to the listed items.
[0038] Further, this description's terminology is not intended to limit the invention. For example, spatially relative terms—such as “beneath”, “below”, “lower”, “above”, “upper”, “proximal”, “distal”, and the like—may be used to describe one element's or feature's relationship to another element or feature as illustrated in the figures. These spatially relative terms are intended to encompass different positions (i.e., locations) and orientations (i.e., rotational placements) of a device in use or operation in addition to the position and orientation shown in the figures. For example, if a device in the figures is turned over, elements described as “below” or “beneath” other elements or features would then be “above” or “over” the other elements or features. Thus, the exemplary term “below” can encompass both positions and orientations of above and below. A device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.
[0039] Further modifications and alternative embodiments will be apparent to those of ordinary skill in the art in view of the disclosure herein. For example, the devices and methods may include additional components or steps that were omitted from the diagrams and description for clarity of operation. Accordingly, this description is to be construed as illustrative only and is for the purpose of teaching those skilled in the art the general manner of carrying out the present teachings. It is to be understood that the various embodiments shown and described herein are to be taken as exemplary. Elements and materials, and arrangements of those elements and materials, may be substituted for those illustrated and described herein, parts and processes may be reversed, and certain features of the present teachings may be utilized independently, all as would be apparent to one skilled in the art after having the benefit of the description herein. Changes may be made in the elements described herein without departing from the spirit and scope of the present teachings and following claims.
[0040] It is to be understood that the particular examples and embodiments set forth herein are non-limiting, and modifications to structure, dimensions, materials, and methodologies may be made without departing from the scope of the present disclosure.
[0041] Other embodiments in accordance with the present disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the exemplary embodiments disclosed herein. It is intended that the specification and examples be considered as exemplary only, with the following claims being entitled to their fullest breadth, including equivalents, under the applicable law.