SURGICAL INSTRUMENT WITH ADJUSTABLE JAWS

Abstract

A surgical instrument, such as a tissue sealing instrument, is provided with an end effector having first and second movable jaws that define a gap therebetween in the closed position for clamping, sealing and/or stapling tissue. The jaws are movable relative to each other in the closed position to reduce a thickness of least one portion of this gap. This configuration allows the jaws to be moved closer together to reduce the overall size of the instrument when, for example, the instrument is introduced and retracted through an opening in the patient, or maneuvered within a body cavity. The surgical instrument may also have multiple settings for use with different staple cartridges, while still maintaining a fixed dimension between the two jaws for clamping, stapling and/or sealing tissue, providing a more adaptable surgical instrument that allows the surgeon to use different staple cartridges without having to change surgical instruments.

Claims

1. A surgical instrument comprising: an end effector comprising a first jaw and a second jaw configured to move relative to each other from an open position to a closed position, wherein the first and second jaws define a gap therebetween in the closed position wherein the first and second jaws are substantially parallel to each other in the closed position; and wherein the first and second jaws are movable relative to each other to adjust a thickness of at least one portion of the gap.

2. The surgical instrument of claim 1, wherein the first and second jaws are movable between the closed position wherein said at least one portion of the gap defines a first thickness between the first and second jaws and an overclosed position wherein said at least one portion of the gap defines a second thickness between the first and second jaws, wherein the first thickness is greater than the second thickness, wherein the first and second jaws are biased towards the closed position.

3. (canceled)

4. (canceled)

5. The surgical instrument of claim 1, wherein the second jaw comprises a distal end portion and a proximal end portion, and wherein the end effector comprises a hinge coupled to the proximal end portion of the second jaw, the second jaw being configured to pivot about the hinge such that the distal end portion is translated towards and away from the first jaw, wherein the second jaw is pivotable about the hinge such that the distal end portion of the second jaw is closer to the first jaw than the proximal end portion of the second jaw is to the first jaw.

6. (canceled)

7. The surgical instrument of claim 5, wherein the distal end portion of the second jaw has an upper surface facing the first jaw, said upper surface being tapered in a distal direction.

8. The surgical instrument of claim 5, wherein the distal end portion of the second jaw has a first height in a direction substantially perpendicular to the longitudinal axis and the proximal end portion of the second jaw has a second height in said direction, the first height being greater than the second height in the closed position.

9. The surgical instrument of claim 2, further comprising an actuator coupled to the end effector, the actuator being configured to move the second jaw between the closed and overclosed positions.

10. The surgical instrument of claim 1, further comprising a rotatable drive member coupled to one of the first jaw or second jaws and configured such that rotation of the rotatable drive member causes translation of the second jaw towards or away from the first jaw to change the thickness of said at least one portion of the gap.

11. The surgical instrument of claim 1, further comprising a cable drive coupled to one of the first and second jaws, the cable drive being configured to translate the first and second jaw towards or away from each other to change the thickness of said at least one portion of the gap.

12. The surgical instrument of claim 2, further comprising: a staple cartridge coupled to one of the first and second jaws and housing a plurality of staples; and a drive member configured to translate distally through the end effector, the drive member being configured to engage the staples upon distal translation of the drive member through the staple cartridge and move the staples from an interior of the staple cartridge to an exterior of the staple cartridge; and a camming surface between the drive member and one of the first or second jaws, the camming surface being configured to advance the first and second jaws from the overclosed position to the closed position as the drive member is translated distally through the staple cartridge.

13. (canceled)

14. The surgical instrument of claim 2, further comprising a locking mechanism coupled to one of the first or second jaws and configured to lock the first and second jaws in one of the closed or overclosed positions.

15. The surgical instrument of claim 12, further comprising: an actuation mechanism in contact with the drive member and configured to translate the drive member distally through the end effector; and an actuator operatively connected to the actuation mechanism, wherein the actuator includes a movable handle of a handle assembly provided at the proximal end portion of the surgical instrument, wherein the actuator includes a control device of a robotic surgical system.

16. (canceled)

17. The surgical instrument of claim 2, wherein each of the first and second jaws have distal end portions and proximal end portions, the jaws being configured to move such that the distal end portions are closer to each other in the overclosed position than in the closed position, wherein each of the first and second jaws have distal end portions and proximal end portions, the jaws being configured to move such that the distal end portions are closer to each other in the overclosed position than in the closed position.

18. (canceled)

19. (canceled)

20. (canceled)

21. (canceled)

22. (canceled)

23. A surgical instrument comprising: a drive member; an end effector comprising a first jaw rotatably coupled to a second jaw; wherein at least one of the first jaw and the second jaw is movable between a first configuration and a second configuration, wherein in the first configuration, a distance separating a distal end of the first jaw from a distal end of the second jaw is less than a distance separating a proximal end of the first jaw from a proximal end of the second jaw; and wherein in the second configuration, the distance separating the distal end of the first jaw from the distal end of the second jaw is approximately equal to the distance separating the proximal end of the first jaw from the proximal end of the second jaw.

24. The surgical instrument of claim 23, wherein the first jaw defines a first longitudinal slot configured to accommodate a first projection of the drive member, and the second jaw defines a second longitudinal slot configured to accommodate a second projection of the drive member, wherein a length of the first longitudinal slot is greater than a length of the second longitudinal slot.

25. The surgical instrument of claim 23, wherein a height of the distal end of the second jaw is greater than a height of the proximal end of the second jaw.

26. The surgical instrument of claim 23, wherein a distance separating an outer surface of the second jaw from a tissue-contacting surface of the second jaw at the distal end of the second jaw is greater than a distance separating the outer surface of the second jaw from the tissue-contacting surface of the second jaw at the proximal end of the second jaw.

27. (canceled)

28. The surgical instrument of claim 24, wherein the first longitudinal slot extends from the proximal end of the first jaw to the distal end of the first jaw, and wherein the second longitudinal slot extends from a midway position between the proximal end of the second jaw and the distal end of the second jaw, to the distal end of the second jaw.

29. The surgical instrument of claim 24, wherein in the first configuration, a distance separating an outer surface of the distal end of the first jaw from an outer surface of the distal end of the second jaw is approximately equal to a distance separating an outer surface of the proximal end of the first jaw from an outer surface of the proximal end of the second jaw, and wherein in the second configuration, the distance separating an outer surface of the distal end of the first jaw from an outer surface of the distal end of the second jaw is greater than the distance separating an outer surface of the proximal end of the first jaw from an outer surface of the proximal end of the second jaw.

30. The surgical instrument of claim 24, wherein in the first configuration, a total cross sectional area of the distal end of the end effector is approximately equal to a total cross sectional area of the proximal end of the end effector, and in the second configuration, a total cross sectional area of the distal end of the end effector is larger than a total cross sectional area of the proximal end of the end effector.

31. The surgical instrument of claim 23, wherein the first jaw defines a first jaw longitudinal axis extending from the proximal end of the first jaw to the distal end of the first jaw, wherein in the first configuration, a tissue-contacting surface of the second jaw is transverse to the first jaw longitudinal axis, and wherein in the second configuration, the tissue-contacting surface of the second jaw is parallel to the first jaw longitudinal axis.

32.-61. (canceled)

Description

BRIEF DESCRIPTIION OF THE DRAWINGS

[0050] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several embodiments of the disclosure and together with the description serve to explain the principles of the disclosure.

[0051] FIG. 1 illustrates a perspective view of an illustrative surgical instrument having an end effector mounted to an elongated shaft;

[0052] FIG. 1A is a perspective top view of the distal end portion of an illustrative surgical instrument with the jaws in the open position;

[0053] FIG. 1B is a bottom perspective view with parts separated of a representative staple cartridge for an illustrative surgical instrument;

[0054] FIG. 1C shows an enlarged view of the cooperative relationship between a portion of a drive member and a plurality of staple pushers and staples which form part of the staple cartridge of FIG. 1B;

[0055] FIG. 1D is a perspective bottom view of the distal end portion of the surgical instrument of FIG. 1A;

[0056] FIG. 2 is a perspective view of the end portion of an illustrative surgical instrument with some parts removed;

[0057] FIG. 3A is a front view of a drive member for the illustrative surgical instrument of FIG. 1;

[0058] FIG. 3B is a side view of the drive member of FIG. 3A;

[0059] FIG. 4A is a partial cross-sectional view of the actuation mechanism for a drive member for use with the surgical instrument of FIG. 1;

[0060] FIG. 4B is a partial cross-sectional view of the actuation mechanism for a drive member for use with the surgical instrument of FIG. 1;

[0061] FIG. 5 is a side view of an actuator mechanism for the illustrative surgical instrument of FIG. 1;

[0062] FIG. 6 is a side view of an end effector of a surgical instrument with parts removed according to certain embodiments of the invention;

[0063] FIG. 7 is a perspective bottom view of one portion of a movable jaw of an end effector according to certain embodiments of the present invention;

[0064] FIG. 8 is a side view of a distal portion of the end effector of FIG. 6;

[0065] FIG. 9 is a top view of distal portion of a movable jaw of an end effector according to certain embodiments of the present invention;

[0066] FIGS. 10A and 10B are side views of a proximal portion of a jaw of an end effector according to certain embodiments of the present invention;

[0067] FIG. 11 is a partially transparent side view of a proximal portion of an end effector according to certain embodiments of the present invention;

[0068] FIG. 12 is a side view of an actuation mechanism for moving jaws of an end effector according to certain embodiments of the present disclosure;

[0069] FIGS. 13A and 13B are partially transparent side views of a proximal portion of an end effector according to certain embodiments of the present disclosure;

[0070] FIG. 14 is a partial cross-sectional view of a proximal portion of an end effector according to certain embodiments of the present disclosure;

[0071] FIG. 15 illustrates a top view of an operating room employing a robotic surgical system utilizing aspects of the present invention; and

[0072] FIG. 16 illustrates a simplified side view of a robotic arm assembly that is usable with various aspects of the present invention.

DETAILED DESCRIPTION

[0073] This description and the accompanying drawings illustrate exemplary embodiments and should not be taken as limiting, with the claims defining the scope of the present disclosure, including equivalents. Various mechanical, compositional, structural, and operational changes may be made without departing from the scope of this description and the claims, 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 aspects 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. Moreover, the depictions herein are for illustrative purposes only and do not necessarily reflect the actual shape, size, or dimensions of the system or illustrated components.

[0074] 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.

[0075] While the following disclosure is presented with respect to a linear surgical stapler where staples are sequentially fired, it should be understood that the features of the presently described surgical instruments may be readily adapted for use in any type of surgical clamping, cutting, or sealing instruments, whether or not the surgical clamping and cutting instrument applies a fastener. For example, the presently described drive member and actuation mechanism may be employed in an electrosurgical instrument wherein the jaws include electrodes for applying energy to tissue to treat (e.g., cauterize, ablate, fuse, or cut) the tissue. The surgical clamping and cutting instrument may be a minimally invasive (e.g., laparoscopic) instrument or an instrument used for open surgery.

[0076] Additionally, the features of the presently described surgical stapling instruments may be readily adapted for use in surgical instruments that are activated using any technique within the purview of those skilled in the art, such as, for example, manually activated surgical instruments, powered surgical instruments (e.g., electro-mechanically powered instruments), robotic surgical instruments, and the like.

[0077] While several embodiments of an illustrative surgical instrument are described below and shown in the drawings, it is not intended that the disclosure be limited to these particular instruments. The embodiments of the present disclosure may be incorporated into the a variety of different surgical instruments, such as those described in commonly-assigned, co-pending U.S. Provisional Patent Application Nos. 62/947307, 62/947,263 and 62/961,504; U.S. patent application Ser. Nos. 16/205,128, 16/678,405 and 16/904,482; and International Patent Nos. PCT/US2019/107646, PCT/US2019/019501, PCT/US2019/062344, PCT/US2019/064861, PCT/US2019/062768, PCT/2020/025655, PCT/US2020/056979, PCT/2019/066513, PCT/US2020/020672 and PCT/US2019/066530 and PCT/US2020/033481, the complete disclosures of which are incorporated by reference herein in their entirety for all purposes as if copied and pasted herein.

[0078] FIG. 1 is a perspective view of an illustrative surgical instrument 100 in accordance with certain embodiments of the present disclosure having a handle assembly 102, and an end effector 110 mounted on an elongated shaft 106 of the surgical stapling instrument 100. End effector 110 includes a first jaw 111 and a second jaw 112. Handle assembly 102 includes a stationary handle 102a and a moveable handle 102b, which serves as an actuator for surgical instrument 100.

[0079] In certain embodiments, handle assembly 102 may include input couplers (not shown) instead of, or in addition to, the stationary and movable handles. The input couplers provide a mechanical coupling between the drive tendons or cables of the instrument and motorized axes of the mechanical interface of a drive system. The input couplers may interface with, and be driven by, corresponding output couplers (not shown) of a telesurgical surgery system, such as the system disclosed in U.S Pub. No. 2014/0183244A1, the entire disclosure of which is incorporated by reference herein for all purposes. The input couplers are drivingly coupled with one or more input members (not shown) that are disposed within the instrument shaft 106 and end effector 110. Suitable input couplers can be adapted to mate with various types of motor packs (not shown), such as the stapler-specific motor packs disclosed in U.S. Pat. No. 8,912,746, or the universal motor packs disclosed in U.S. Pat. No. 8,529,582, the disclosures of both of which are incorporated by reference herein in their entirety for all purposes. Further details of known input couplers and surgical systems are described, for example, in U.S. Pat. Nos. 8,597,280, 7,048,745, 10,016,244. Each of these patents is hereby incorporated by reference in its entirety for all purposes.

[0080] Actuation mechanisms of surgical instrument 100 may employ drive cables that are used in conjunction with a system of motors and pulleys. Powered surgical systems, including robotic surgical systems that utilize drive cables connected to a system of motors and pulleys for various functions including opening and closing of jaws, as well as for movement and actuation of end effectors are well known. Further details of known drive cable surgical systems are described, for example, in U.S. Pat. Nos. 7,666,191 and 9,050,119 both of which are hereby incorporated by reference in their entireties for all purposes. While described herein with respect to an instrument configured for use with a robotic surgical system, it should be understood that the wrist assemblies described herein may be incorporated into manually actuated instruments, electro-mechanical powered instruments, or instruments actuated in any other way.

[0081] FIG. 1A illustrates the distal end portion of surgical instrument 100, including an end effector 110 having first and second jaws 111, 112, a clevis 140 for mounting jaws 111, 112 to the instrument, and an articulation mechanism, such as a wrist 160. First jaw 111 includes an anvil 115 having staple-forming pockets 116 (see FIG. 1D). In certain embodiments, second jaw 112 is a movable jaw configured to move from an open position to a closed position relative to first jaw 111. In other embodiments, first jaw 111 is a movable jaw configured to move between open and closed positions relative to second jaw 112. In still other embodiments, both jaws 111, 112 are movable relative to each other. In the open position, a fresh stapling cartridge 122 (sometimes referred to as a reload and shown more clearly in FIG. 1B) can be loaded into movable jaw 112 and tissue may be positioned between the jaws 111, 112. In the closed position, jaws 111, 112 cooperate to clamp tissue such that cartridge 122 and anvil 115 are in close cooperative alignment. Movable jaw 112 is configured to move from an open position to a closed position relative to stationary jaw 111.

[0082] Referring now to FIGS. 1B and 1C, a representative staple cartridge 122 may include a plurality of staple assemblies, each comprising one or more staples 124 supported on corresponding staple drivers or pushers 126 provided within respective staple apertures 127 formed in cartridge 122. In certain embodiments, the staple assemblies each include at least one (preferably 2-4) staple pushers 126 removably coupled to at least one (preferably 2-4) staples 124. The staple assemblies are preferably arranged within apertures 127 such that staple pusher 126 is situated near a bottom surface of staple cartridge 122 and staples 124 have their legs facing a top surface of cartridge 122. For ease of reference, the top surface of cartridge 122 faces fixed jaw 111 (see FIG. 1). As discussed above, the entire staple cartridge 122 can be loaded into movable jaw 112 for use in surgery as described in more detail below. In certain embodiments, staple pusher(s) 126 include one or more supporting elements extending above their top surface for providing support to staples 124 when they are resting thereon. Of course, other suitable geometric designs of staple pusher 126 may be used to receive and hold staple 124 in accordance with the present invention. For example, pusher 126 may have a recess (not shown) for receiving staple 124, as is described in commonly-assigned, co-pending International Patent Application No. PCT/US2020/033481, previously incorporated herein by reference. Alternatively, pusher 126 may have a flatter upper surface (i.e., without a recess or pocket) that allows the backspan of staple 124 to rest thereon.

[0083] Cartridge 122 also may include a shuttle 123 having an inclined distal surface 125 that, upon distal movement, sequentially acts on staple pushers 126, camming them upwardly, thereby moving staples 124 into deforming contact with anvil 115 (See FIG. 1D). Shuttle 123 may be part of a drive member 150 (FIGS. 3A and 3B) described in more detail below. In certain embodiments, drive member 150 may also include a knife 128 configured to translate distally through a channel 119 in cartridge 122 and to sever clamped, stapled tissue (see FIG. 3A). In embodiments, knife 128 may simply be a sharpened edge on drive member 150 rather than a distinct structure within the cartridge. Cartridge 122 may be removably received within movable jaw 112 or, in single use embodiments, may be manufactured as part of movable jaw 112.

[0084] In certain embodiments, jaws 111, 112 are attached to surgical instrument 100 via clevis 140. Clevis 140 includes upper and lower portions that cooperate when assembled to form a protrusion 145 configured to engage tabs 113 (see FIG. 1A) of jaw 111 to securely mount jaw 111 in a fixed position on instrument 100. Clevis further includes an opening for receiving a pivot pin 130 defining a pivot axis around which jaw 112 pivots as described in more detail below. A more complete description of a suitable clevis 140 for use with the present invention may be found in commonly-assigned, co-pending provisional patent application Nos. 62,783,444, filed Dec. 21, 2018; 62,783,481, filed Dec. 21, 2018; 62,783,460, filed Dec. 21, 2018; 62,747,912, filed Oct. 19, 2018; and 62,783,429, filed Dec. 21, 2018, the complete disclosures of which are hereby incorporated by reference in their entirety for all purposes. Of course, it will be recognized by those skilled in the art that other coupling mechanisms known by those skilled in the art may be used with the present invention to attach the jaws 11, 112 to the proximal portion of surgical instrument 100.

[0085] Referring now to FIG. 2, end effector 110 may be articulated in multiple directions by an articulation mechanism. In certain embodiments, the articulation mechanism may be a wrist 160 as shown, although other articulation mechanisms are contemplated. A preferred embodiment of wrist 160 includes a plurality of articulation joints 162, 164, 166, etc. that define a bore 167 through which an actuation mechanism (in embodiments, coil 120 and drive cable 171, see FIGS. 3A and 3B) may pass. Upon exiting articulation wrist 160, coil 120 enters and passes through a channel 144 within clevis 140, ultimately engaging bore 158 of upper shoe 152 of drive member 150 (discussed in more detail below). Other articulation mechanisms known by those skilled in the art may substitute for wrist 160 as shown for example in U.S. Publication. No. 2015/0250530 the entire disclosure of which is hereby incorporated by reference in its entirety for all purposes.

[0086] Upon actuation of the surgical instrument, drive member 150 is advanced distally through end effector 110 to move jaws 111, 112 from the open position to the closed position, after which shuttle 123 and knife 128 are advanced distally through cartridge 122 to staple and cut tissue grasped between jaws 111, 112. Drive member 150 may be any structure capable of pushing at least one of a shuttle or a knife of a surgical stapling instrument with the necessary force to effectively sever or staple human tissue. Drive member 150 may be an I-beam, an

[0087] E-beam, or any other type of drive member capable of performing similar functions. Drive member 150 is movably supported on the surgical stapling instrument 100 such that it may pass distally through cartridge 122 and upper fixed jaw 111 and lower jaw 112 when the surgical stapling instrument is fired (e.g., actuated).

[0088] As seen in FIGS. 3A and 3B, an illustrative drive member 150 may include a body having an upper projection or shoe 152, a lower projection or shoe 154, a central portion 156 and first and second lateral portions 159. Lateral portions 159 are the fins that form shuttle 123 shown earlier. Lateral portions 159 of drive member 150 each comprise distal inclined surfaces or ramps 161 that engage with pushers 126 to drive pushers 126 (and the associated staples 124) vertically or perpendicular to the longitudinal axis of shaft 106 when drive member 150 is translated distally. In a preferred embodiment, shuttle fins 159 are integrated into lower shoe 154 of drive member 150. Integrating shuttle fins 159 into drive member 150 provides more flexibility in the design of staple cartridge 122. For example, this may allow for a reduction in the size of staple cartridge 122 and surgical instrument 100 and/or increasing the length of staples 124 for a given size of surgical instrument 100.

[0089] Referring now to FIGS. 4A and 4B, actuation assembly 190 includes a drive cable 171, a coil 120, a sheath 121 surrounding coil 120, and a drive rod 175. Drive cable 171 includes an enlarged distal end 173. Upper shoe 152 of drive member 150 includes a bore 158 into which drive cables 171 are routed. When assembling illustrative surgical instrument 100, coil 120 and a protective sheath 121 are slipped over the free end of drive cable 171. The free end of drive cable 171 is attached to a drive rod 175 securing coil 120 and the protective sheath 121 between drive member 150 and drive rod 175 as best seen in FIG. 3B). Sheath 121 may function to promote stability, smooth movement, and prevent buckling upon actuation of surgical instrument 100. Sheath 121 may be made from polyimide, or any other suitable material having the requisite strength requirements such as various reinforced plastics, a nickel titanium alloy such as NITINOL™, poly para-phenyleneterphtalamide materials such as KEVLAR™ commercially available from DuPont. Those of skill in the art may envision other suitable materials.

[0090] Enlarged distal end 173 of drive cable 171 resides within an enlarged distal portion 159 of bore 158 in upper shoe 152 of body 150, such that the proximal face 157 of enlarged distal end 173 may apply a retraction force on upper shoe 152 when the drive cable 171 is pulled proximally, i.e., in the direction of arrow “B” in FIG. 3B. Proximal surface 153 of upper shoe 152 is configured to be engaged by a coil 120 of actuation assembly 190 such that coil 120 may apply force to upper shoe 152 to advance drive member 150 distally, i.e., in the direction of arrow “A” in FIG. 3B. Drive rod 175 is operationally connected to an actuator (e.g., movable handle 102b), which allows distal translation and proximal retraction of actuation assembly 190. Those skilled in the art will recognize that in a manually actuated instrument, the actuator may be a movable handle, such as moveable handle 102b shown in FIG. 1; in a powered instrument the actuator may be a button (not shown) that causes a motor to act on the drive rod; and in a robotic system, the actuator may be a control device such as the control devices described below in connection with FIGS. 14 and 15. Any suitable backend actuation mechanism for driving the components of the surgical stapling instrument may be used. For additional details relating to exemplary actuation mechanisms using push/pull drive cables see, e.g., commonly assigned, co-pending International Application No. WO 2018/049217, the disclosure of which is hereby incorporated by reference in its entirety for all purposes.

[0091] Referring now to FIG. 5, upper shoe 152 of drive member 150 is substantially aligned with and translates through a channel 118 in fixed jaw 111, while lower shoe 154 of drive member 150 is substantially aligned with and translates through a channel (not shown) in jaw 112 and below jaw 112. During actuation of illustrative surgical instrument 100, drive rod 175 applies force to coil 120, thereby causing coil 120 to apply force to upper shoe 152 of drive member 150, translating it distally (i.e., in the direction of arrow “A” in FIG. 3B) initially closing jaws 111,112 and then ejecting staples 124 from cartridge 122 to staple tissue. After stapling is complete, drive rod 175 applies a force in the proximal direction to effect retraction of drive member. During retraction, enlarged distal end 173 of drive cable 171 is obstructed by wall 157 of enlarged portion 159 of bore 158, causing drive cable 171 to apply force to upper shoe 152 of drive member 150, thereby translating drive member 150 in the proximal direction. One of ordinary skill in the art will appreciate that drive member 150, drive cable 171, and drive rod 175 all move in unison and remain in the same relative position to each other.

[0092] In use, in the open configuration, drive member 150 is positioned proximally of cam surface 114 formed on movable jaw 112. As drive member 150 translates in the distal direction, movable jaw 112 will rotate towards the closed position around pivot 117. Once drive member 150 has come into contact with cam surface 114 of movable jaw 112, lower portion 154 of drive member 150 rides underneath cam surface 114, drive member 150 pushes movable jaw 112, causing it to pivot towards the closed position. In the closed position, drive member 150 has translated distally past cam surface 114. In this position, tissue is clamped, and further advancement of the drive member will sever and staple tissue. Of course, it will be recognized by those skilled in the art that drive member 150 may be any structure capable of pushing at least one of a shuttle or a knife of a surgical stapling instrument with the necessary force to effectively sever or staple human tissue. Drive member 150 may be an I-beam, an E-beam, or any other type of drive member capable of performing similar functions. Drive member 150 is movably supported on the surgical stapling instrument 100 such that it may pass distally through a staple cartridge and upper fixed jaw 111 and lower jaw 112 when the surgical stapling instrument is fired (e.g., actuated).

[0093] Referring now to FIG. 6, a preferred embodiment of end effector 110 according to the present disclosure includes fixed jaw 111 and movable jaw 112 as discussed above in relation to the illustrative surgical instrument 100. Movable jaw 112 includes a staple cartridge 122 for housing staples 126, as discussed above and shown in FIG. 1B. Jaw 112 preferably has an upper surface 202 opposite a lower surface 204 of fixed jaw 111. In the closed position of jaws 111, 112, upper and lower surfaces 202, 204 define a gap 206 therebetween that provides clearance space for tissue after the tissue has been clamped by jaws 111, 112. In the exemplary embodiment, upper surface 202 is substantially parallel to lower surface 204 in the closed position such that gap 206 has a fixed dimension along the longitudinal axis of end effector 110 (note that the closed position is not shown in FIG. 6). The thickness of this tissue gap 206 will depend on the clinical application, e.g., the amount of tissue to be clamped, the height of staples 124, etc.

[0094] Fixed and movable jaws 111, 112 include first and second longitudinal slots, respectively, (not shown) each configured to receive a lateral projection from drive member 150. In the preferred embodiment, the length of the first longitudinal slot (i.e., in the fixed jaw 111) is greater than the length of the second longitudinal slot in the movable jaw 112. In certain embodiments, the first longitudinal slot extends from the proximal end of fixed jaw 111 to the distal end of fixed jaw 111, and the second longitudinal slot extends from about a midway position between the proximal end of movable jaw 112 and the distal end of the second jaw, to the distal end of movable jaw 112. In the overclosed position, drive member 150 is in a retracted position in which the second lateral projection of drive member 150 is not engaged with movable jaw 112 and is not received within the second longitudinal slot of movable jaw 112.

[0095] Movable jaw 112 is pivotally coupled to fixed jaw 111 by a hinge 210 positioned at the proximal end portion of end effector 110. Hinge 210 preferably comprises a pin 130 or other suitable projection that extends through a hole (not shown) in a joint structure 214 coupled to the proximal portion of movable jaw 112. Pin 130 acts as a pivot to allow movable jaw 112 to pivot relative to fixed jaw 111 about the axis extending through pin 130. Of course, other suitable hinges may be used with the present disclosure, such as a bolt, joint hinge, strap hinge, butterfly, barrel, piano, pivot, spring, “living hinges” and the like. In the exemplary embodiment, hinge 210 allows movable jaw 112 to pivot from an open position, wherein movable jaw 112 extends downward from fixed jaw 111 such that an area larger than tissue gap 206 exists between jaws 111, 112 (see, for example, FIG. 1A), to a closed position, wherein upper and lower surfaces 202, 204 of jaws 111, 112 are substantially parallel to each other, as discussed above. In addition, and according to the present disclosure, hinge 200 allows movable jaw 112 to pivot upwards from the closed position towards fixed jaw 111 into an “overclosed” position (shown in FIG. 6) wherein at least a portion of tissue gap 206 has a smaller thickness than in the closed position.

[0096] In particular and as shown in FIG. 8, a distal end portion 216 of movable jaw 112 is closer to fixed jaw 111 in the overclosed position such that tissue gap 206 is no longer parallel. Thus, upper surface 202 of movable jaw 112 extends at an angle relative to the longitudinal axis of end effector 110 in the overclosed position. In the exemplary embodiment, this angle is between about 0.4 to about 2.0 degrees, preferably between about 0.5 to about 1.0 degrees and more preferably about 0.55 degrees relative to the longitudinal axis of end effector 110.

[0097] In the overclosed position, the distance separating an outer surface of the distal end of fixed jaw 111 from an outer surface of the distal end of movable jaw 112 is approximately equal to a distance separating an outer surface of the proximal end of fixed jaw 111 from an outer surface of the proximal end of movable jaw 112. In the closed position, the distance separating an outer surface of the distal end of fixed jaw 111 from an outer surface of the distal end of movable jaw 112 is greater than the distance separating an outer surface of the proximal end of fixed jaw 111 from an outer surface of the proximal end of movable jaw 112. Thus, the total cross sectional area of the distal end of end effector 110 is approximately equal to the total cross sectional area of the proximal end of end effector 110 in the overclosed position. However, the total cross sectional area of the distal end of end effector 110 is larger than the total cross sectional area of proximal end of end effector in the closed position.

[0098] In the overclosed position, the tissue contact surface of movable jaw 112 and the second longitudinal slot in movable jaw 112 are not parallel (i.e., transverse) to the longitudinal axis of fixed jaw 111. In the closed position, the tissue contact surface of movable jaw 112 and the second longitudinal slot in movable jaw 112 are substantially parallel to the longitudinal axis of fixed jaw 111

[0099] Referring now to FIG. 7, movable jaw 112 preferably comprises a curved lower surface 220 that extends below jaw 112 from one side of upper surface 202 to the other side of upper surface 202. In certain embodiments, lower surface 220 further includes a proximal portion 222 that is recessed from the rest of lower surface 220. Essentially, a small amount of material is cut away from lower surface 220 at proximal portion 222 after the part has been molded such that proximal portion 222 has a smaller radius than a distal portion 224 of jaw 112 in the closed position. The depth and overall size of the recess in proximal portion 222 is preferably designed to provide sufficient room for tissue gap 206 to be taken up distally, while maintaining suitable stiffness for jaw 112 in operation. In addition, the recess in proximal portion 222 is preferably sized to limit any sharp edges created wherein the recess intersects the track or channel 119 in jaw 112. Removing this material from proximal portion 222 of lower surface 220 reduces the overall cross-sectional size of end effector 110 such that lower surface 220 of jaw 112 is substantially coradial with the upper surface of fixed jaw 111 in the overclosed position. (i.e., proximal portion 222 does not “stick out” below end effector 110 when distal portion 224 is pivoted upwards into the overclosed position). This allows the entire end effector 110 to fit within a cannula having a smaller radius when jaws 111, 112 are placed into the overclosed position.

[0100] Alternatively, the entire lower surface 220 of jaw 112 may be designed with an incline that substantially matches the angle that jaw 112 makes with the longitudinal axis of end effector 110 in the overclosed position (i.e., about 0.4 to about 2.0 degrees, preferably about 0.5 to about 1.0 degrees and more preferably about 0.55 degrees relative to the longitudinal axis). The incline extends in the proximal direction such that distal portion 224 of jaw 112 is further away from jaw 111 than proximal portion 222 in the closed position. In this configuration, lower surface of jaw 112 will be substantially parallel to the longitudinal axis in the overclosed position and end effector 110 will have a small cross-sectional area.

[0101] In an exemplary embodiment, hinge 210 is not locked into any one position such that movable jaw 112 may freely pivot from the open position (FIG. 1A), through the closed “parallel” position (not shown), to the overclosed position shown in FIGS. 6 and 8. Hinge 210, however, is configured to limit movable jaw 112 from moving beyond the overclosed or open positions (i.e., the freedom of movement is limited to the angle between the overclosed and open positions). Hinge 210 may be biased towards the open position such that movable jaw 112 will move into this position unless constrained. In certain embodiments, the surgical instrument further comprises a spring (not shown) configured to apply a jaw-opening force to at least one of the fixed and movable jaws 111, 112. Alternatively, movable jaw 112 may be positioned below fixed jaw 111 during operation such that gravity automatically biases movable jaw 112 towards the open position. In the preferred embodiment, drive member 150 is proximal to movable jaw 112 in its insertion or “home” position so that it does not interfere with the pivoting of jaw 112.

[0102] In use, the operator (e.g., surgeon) holds jaws 111, 112 together in the overclosed position before inserting end effector 110 into a cannula or other percutaneous penetration in the patient. Once in the cannula, the internal surface of the cannula will hold jaws 111, 112 in the overclosed position, thereby reducing the radius of end effector 110 and allowing end effector 110 to fit through a smaller cannula. After end effector 110 passes through the cannula and into a body cavity of the patient, movable jaw 112 will pivot from the overclosed position through the closed position and into the open position for placing tissue into jaws 111, 112 at the target site within the patient. The surgeon may then place jaws 111, 112 around the target tissue and actuate drive member 150 to move distally and come into contact with cam surface 114 of movable jaw 112. As discussed previously, lower portion 154 of drive member 150 rides underneath cam surface 114 and drive member 150 pushes movable jaw 112, causing it to pivot towards the closed position (see FIG. 5). In the closed position. drive member 150 has translated distally past cam surface 114. In this position, tissue is clamped, and further advancement of the drive member will sever and staple tissue.

[0103] Upon completion of the surgical operation, end effector 110 is retracted through the cannula or percutaneous penetration in the patient. The inner surface of the cannula forces movable jaw 112 back into the overclosed position so that the cross-sectional area of end effector 110 is small enough to fit through the cannula. Thus, the tissue gap 206 that is necessary for clamping onto tissue can at least be partially eliminated in the overclosed position so that the end effector 110 can be made smaller for insertion or retraction through the cannula.

[0104] In an alternative embodiment, surgical instrument 100 includes a locking mechanism (not shown) for locking hinge 210 into either the closed or the overclosed positions. In the latter instance, the end effector 110 may be freely moved around within the body cavity of the patient in the overclosed position, making it more compact and maneuverable. The locking mechanism may be coupled to a suitable actuator on the proximal handle (or as part of a robotic control system) so that the operator may unlock hinge 210 and allow it to pivot into the open position. Alternatively, drive member 150 may include a camming or other surface that engages the locking mechanism to unlock hinge 210. In this latter embodiment, the camming surface may reside on a distal or proximal end portion of drive member 150 such that distal or proximal movement of drive member 150 engages the locking mechanism to unlock hinge 210 and allow jaw 112 to pivot away from jaw 111 into the open position. The locking mechanism may include a spring-loaded unlocking/locking member (not shown). In this embodiment, distal translation of drive member 150 would allow the locking/unlocking member the freedom to move in the direction of spring force to, for example, unlock hinge 210 and allow jaws 111, 112 to pivot freely. Proximal translation of drive member 150 forces the locking/unlocking mechanism back in the direction opposite the spring force to lock hinge 210 in the overclosed position.

[0105] Referring now to FIG. 9, another embodiment of staple cartridge 122 includes a top surface 230 with pockets 116 for housing staples 124 (not shown).

[0106] In this embodiment, top surface 230 of cartridge 122 includes a distal end portion 232 that is inclined relative to a proximal portion 234 of surface 230. In particular, distal end portion 232 is inclined downward towards the distal tip 235 of cartridge 122 so as to provide more clearance in tissue gap 206 between jaws 111, 112 in the overclosed position. In the exemplary embodiment, distal end portion 232 is inclined at an angle relative to the longitudinal axis of end effector 110 that substantially matches the angle formed by movable jaw 112 with fixed jaw 111 in the overclosed position. This configuration provides clearance for movable jaw 112 to be moved into the overclosed position without contacting lower surface 204 of fixed jaw 111. Certain staple cartridges 122 are larger than others (e.g., taller staples) and other staple cartridges 122 are designed with camber such that the distal end portion has a tighter tissue gap than the proximal end portion. These latter staple cartridges 122 are typically used on tissue or blood vessels that are not placed at the tip of the device (i.e., vessels that are clamped in the central and/or proximal portion of jaws 111, 112). This embodiment allows use of those types of suture cartridges with the present invention.

[0107] FIGS. 10-13 illustrate embodiments of the present disclosure for setting multiple thicknesses for tissue gap 206 between jaws 111, 112. In these embodiments, drive member 150 has first and second lateral projections and fixed jaw 111 defines first and second longitudinal slots each configured to accommodate the first lateral projection of drive member 111. Movable jaw 112 defines a third longitudinal slot configured to accommodate the second lateral projection of drive member 150. During a first operational mode, the first lateral projection travels within the first longitudinal slot of fixed jaw 111. During a second operational mode, the first lateral projection travels within the second longitudinal slot of the fixed jaw 111. The surgical instrument further comprises an actuator configured to switch between the first operational mode and the second operational mode. FIGS. 10-13 illustrate different embodiments of the actuator.

[0108] Referring now to FIGS. 10A and 10B, in one embodiment, fixed jaw 111 includes a slide plate 238 and a projection or pin 240 extending laterally outward from the body of jaw 111 through an opening in slide plate 238. Pin 240 is configured to extend through an opening 242 in a second slide plate 246 coupled to drive member 150 such that pin 240 cooperates with a camming surface 244 in plate 246. Alternatively, plate 246 may be coupled to, or integral with jaw 111 with pin 240 extending from drive member 150. As drive member 150 is translated distally, camming surface 244 motivates projection 240 (and jaw 111 therewith) upward relative to movable jaw 112 (not shown in FIGS. 9A and 9B). This increases the thickness of tissue gap 206. Alternatively, projection 240 and slide plate 246 may cooperate with movable jaw 112 such that movable jaw 112 is configured to translate relative to fixed jaw 111. In use, jaws 111, 112 are set in the overclosed position (FIG. 10A) during insertion, removal and maneuvering of the device within the patient. When the operator is prepared to clamp tissue, drive member 150 is moved distally, causing fixed jaw 111 to translate in a direction substantially perpendicular to the longitudinal axis of end effector 110 (i.e., away from movable jaw 112). This increases the size of the entire tissue gap 206 to allow room for clamping tissue. In this embodiment, jaws 111, 112 may remain substantially parallel to each other in both the closed and overclosed positions.

[0109] Referring now to FIG. 11, another embodiment of the present invention includes a linkage 250 coupling fixed jaw 111 with drive member 150 (not shown in FIG. 11). As shown, linkage 250 includes first and second coupling elements 252, 254 pivotally coupled together with a hinge pin 256. First coupling element 252 is coupled to drive member 150 and second coupling element 254 is coupled to jaw 111. In use, drive member 150 is translated longitudinally, causing coupling elements 252, 254 to pivot about hinge 256 and translate jaw 111 in a transverse direction to the longitudinal axis, thereby moving jaw 111 towards and away from movable jaw 112 and changing the thickness of tissue gap 206. As in the previous embodiment, linkage 250 may couple drive member 150 to movable jaw 112 in a similar manner. Alternatively, linkage 250 may be coupled to a proximal actuator (not shown) that moves one or both jaws 111, 112 independently of drive member 150. In this embodiment, the operator, for example, may engage the actuator from handle 102, or from another user interface such as a robotic control device, to move jaws 111, 112 between the closed and overclosed positions.

[0110] FIG. 12 illustrates yet another embodiment of the present invention. As shown, end effector 110 includes a rotatable drive assembly 260 comprising a drive member 262 rotatably coupled to a proximal end portion of end effector 110 by a pin 266 or other suitable hinge. A linkage 264 is pivotally coupled to fixed jaw 111 and movable jaw 112. Drive member 262 is configured to rotate about pin 266 and engage linkage 264, causing linkage 264 to pivot about pins 268 or other suitable hinges in jaws 111, 112. Linkage 264 pivots and causes fixed jaw 111 to translate distally and downwards relative to movable jaw 112 into the overclosed position, thereby reducing the tissue gap 206 therebetween. Alternatively, linkage 264 may be designed to translate movable jaw 112 relative to fixed jaw 111. In yet another alternative, drive member 262 may be coupled to drive member 150 and configured to rotate upon distal or proximal translation of drive member 150. End effector 110 may further include a locking mechanism to hold drive member 262 in position (either in the closed or overclosed position of jaws 111, 112). Note that jaws 111, 112 may remain substantially parallel to each other in both the closed and overclosed positions. This allows the operator to set multiple tissue gap settings for different staple cartridges, as discussed in more detail below.

[0111] FIGS. 13A and 13B illustrate another embodiment for moving jaws 111, 112 between the closed and overclosed positions. As shown in FIG. 13A, a laser-cut tube 280 is coupled to a cam mover plate 282 having an opening 284 defining an inclined camming surface 286. Fixed jaw 111 includes a projection or pin 288 that extends through opening 284 in plate 282. Tube 280 may be coupled to drive member 150 or a suitable actuator at the proximal end of instrument 100.

[0112] Translation of drive member 150 and/or actuation by the operator via a user interface causes tube 280 to translate in the distal direction, thereby translating cam mover plate 282. Pin 288 on jaw 111 is cammed upwards to translate jaw 111 away from jaw 112 (see FIG. 13B). This moves jaws 111, 112 from the overclosed position (FIG. 13A) to the closed position (FIG. 13B). Cam mover plate 282 may also include a second opening 290 for receiving a projection or pin 292 on lower movable jaw 112. Second opening 290 may also have a cammed surface such that both jaws 111, 112 are translated vertically upon longitudinal translation of tube 280 and plate 282. Alternatively, cam mover plate 282 may only have cammed surfaces that engage lower movable jaw 112.

[0113] Of course, it will be recognized that the present invention is not limited to the embodiments shown above for moving first and second jaws 111, 112 between the closed and overclosed positions. For example, instrument 100 may include an actuator, such as the cable drive actuator described above in reference to drive member 150, that is coupled to a user interface on the proximal handle of instrument 100 or to a robotic control assembly (discussed below). The actuator may be designed to drive a rack-pinion, gear-gear drive, cable or belt drive or other suitable driving mechanism to translate one of the jaws up and down relative to the other one. In this embodiment, the cable drive actuator may be suitably coupled to one or both of jaws 111, 112 to allow the operator to move jaws 111, 112 between the closed and overclosed positions through the proximal interface. A locking/unlocking mechanism may be coupled to either the cable drive or the driving mechanism to hold the mechanism in place at a selected jaw position.

[0114] Referring now to FIG. 14, another aspect of the invention comprises a system and method for setting multiple tissue gap distances for jaws 111, 112 in the closed position. In these embodiments, surgical instrument 100 may be used with suture cartridges 122 of differing sizes, e.g., taller or shorter staples. Alternatively, the surgeon may choose to set different tissue gap distances at selected portions of the surgical procedure (e.g., reduce the thickness of gap 206 during insertion/removal of the device and increase the thickness of gap 206 when clamping and/or stapling tissue).

[0115] Referring now to FIG. 14, another aspect of the invention comprises a system and method for setting multiple tissue gap distances for jaws 111, 112 in the closed position. In these embodiments, surgical instrument 100 may be used with suture cartridges 122 of differing sizes, e.g., taller or shorter staples. Drive member 150 and jaws 111, 112 cooperate with each other such that the upper surface of each of the staple cartridges remains at the same fixed distance from fixed jaw 111 regardless of the height of each of the staple cartridges. This allows the surgical instrument to have multiple settings for use with different staple cartridges, while still maintaining a fixed dimension between the jaws 111, 112 for clamping, stapling and/or sealing tissue. Alternatively, the surgeon may choose to set different tissue gap distances at selected portions of the surgical procedure (e.g., reduce the thickness of gap 206 during insertion/removal of the device and increase the thickness of gap 206 when clamping and/or stapling tissue).

[0116] In one embodiment, fixed jaw 111 comprises an inner surface 270 having first and second longitudinal projections 272, 274 extending substantially along the entire length of jaw 111. Projections 272, 274 define first and second longitudinal tracks or channels 276, 278 along inside surface 270 of jaw 111. Channels 276, 278 are preferably parallel and spaced from each other in a substantially perpendicular direction to the longitudinal axis of end effector 110. Channels 276, 278 are sized to receive upper shoe 152 of drive member 150 such that, when drive member 150 is translated distally, upper shoe 152 passes through one of the channels 276, 278. Lower shoe 154 of drive member 150 is preferably coupled to movable jaw 112. Alternatively, the first and second longitudinal channels may be formed in movable jaw 112 or staple cartridge 122 and sized to receive lower shoe 154 of drive member 150. In this embodiment, upper shoe 252 of drive member 150 may be coupled to fixed jaw 111. In both embodiments, drive member 150 may be aligned with one of the channels in movable jaw 112 to set the gap distance between jaws 111, 112.

[0117] Instrument 100 further includes an actuator or other suitable gearing mechanism (not shown) for moving drive member 150 upwards and downwards relative to jaw 111 such that upper shoe 152 is aligned with one of the channels 276, 278. The actuator may include a cable drive, rotatable drive member, push rod, wedge or other camming surface, screw rod, rack-pinion or other suitable mechanism for translating drive member 150 relative to channels 276, 278. The actuator and/or gearing mechanism may be coupled to drive member 150 and configured to translate drive member vertically upon distal or proximal movement of drive member 150. Alternatively, it may be coupled to a user interface on the proximal handle of instrument 100 or as part of a robotic control assembly and configured for direct user control of jaw settings. In one such embodiment, a rotatable gear mechanism (not shown) is configured to move jaw 111 up and down and to move a cam lock into position to lock the jaw 111 into a particular setting.

[0118] When drive member 150 is aligned with upper channel 276, the distance between lower surface 204 of jaw 111 and lower shoe 154 of drive member 150 is greater than the distance between these two components when drive member 150 is aligned with lower channel 278. This provides multiple settings or gap distances between jaws 111, 112. In one embodiment, these multiple settings may be used to load suture cartridges 122 having different heights. For example, a suture cartridge with relatively taller staples may be loaded into movable jaw 112 such that drive member 150 is automatically aligned with upper channel 276. In another example, a suture cartridge having shorter staples may be loaded into jaw 112 such that drive member 150 is aligned with lower channel 278. In this manner, the gap distance 206 between jaws 111, 112 can be substantially the same with suture cartridges having different heights (e.g., taller or shorter staples).

[0119] Of course, it will be recognized by those skilled in the art that the invention is not limited to two channels or tracks for drive member 150, and may include 3, 4 or more channels depending on the number of differently-sized suture cartridges that are desired for use with the same surgical instrument. The invention may include a surgical instrument set (not shown) having a surgical instrument such as the one described herein and a plurality of different staple cartridges (only one type of staple cartridge 122 is shown in the figures). Each of the staple cartridges 122 are removably couplable to jaw 122 and may have different heights relative to the longitudinal axis of end effector 110. The end effector is configured such that the thickness of 206 gap between jaws 111, 112 will remain the same regardless of the height of the individual staple cartridge.

[0120] In an alternative embodiment, the multiple channel design may be used to change the tissue gap distance between jaws 111, 112 during a surgical operation. For example, drive member 150 may be aligned with upper channel 276 during insertion, removal and maneuvering of the instrument (to reduce the gap distance and the overall cross-sectional dimensions of end effector 110). Prior to or during actuation, drive member 150 may be translated downwards into alignment with lower channel 278 to increase the gap distance between jaws 11, 112 for clamping tissue.

[0121] In another embodiment, drive member 150 comprises a plurality of upper and/or lower shoes (not shown) that are situated parallel to each other, but offset in a direction substantially perpendicular to the longitudinal axis. In this embodiment, drive member 150 can be translated upwards or downwards such that one of the upper and/or lower shoes is aligned with one or more channels in jaws 111, 112. Similar to the above embodiments, drive member 150 may be translated with an actuator, gear drive, camming surface or other suitable mechanism to allow the drive member to be engaged at multiple settings, thereby defining multiple gap distances between jaws 111, 112. Alternatively, drive member 150 may have an upper or lower shoe that is movably coupled to the main body of drive member 150. In this configuration, the upper or lower shoe(s) may be translated vertically relative to body 151 and then fixed into a position that corresponds with one of the channels in end effector 110.

[0122] In yet another embodiment, staple cartridge 122 comprises a longitudinal channel (not shown) for receiving a portion of drive member 150, such as the upper or lower shoes, or another projection. In this embodiment, the vertical height of the channel in staple cartridge 122 will determine the gap distance between jaws 111, 112. Thus, staple cartridges 122 having different heights may be used with the same surgical instrument without changing the gap distance between jaws 111, 112. Alternatively, staple cartridges 122 with the same height may be designed with varying channel heights to vary the actual gap distance (depending on the desired clinical effect).

[0123] FIG. 15 illustrates, as an example, a top view of an operating room employing a robotic surgical system. The robotic surgical system in this case is a robotic surgical system 300 including a Console (“C”) utilized by a Surgeon (“S”) while performing a minimally invasive diagnostic or surgical procedure, usually with assistance from one or more Assistants (“A”), on a Patient (“P”) who is lying down on an Operating table (“O”).

[0124] The Console includes a monitor 304 for displaying an image of a surgical site to the Surgeon, left and right manipulatable control devices 308 and 309, a foot pedal 305, and a processor 302. The control devices 308 and 309 may include any one or more of a variety of input devices such as joysticks, gloves, trigger-guns, hand-operated controllers, or the like. The processor 302 may be a dedicated computer that may be integrated into the Console or positioned next to it.

[0125] The Surgeon performs a minimally invasive surgical procedure by manipulating the control devices 308 and 309 (also referred to herein as “master manipulators”) so that the processor 302 causes their respectively associated robotic arm assemblies, 328 and 329, (also referred to herein as “slave manipulators”) to manipulate their respective removably coupled surgical instruments 338 and 339 (also referred to herein as “tools”) accordingly, while the Surgeon views the surgical site in 3-D on the Console monitor 304 as it is captured by a stereoscopic endoscope 340.

[0126] Each of the tools 338 and 339, as well as the endoscope 340, may be inserted through a cannula or other tool guide (not shown) into the Patient so as to extend down to the surgical site through a corresponding minimally invasive incision such as incision 366. Each of the robotic arms is conventionally formed of links, such as link 362, which are coupled together and manipulated through motor controlled or active joints, such as joint 363.

[0127] The number of surgical tools used at one time and consequently, the number of robotic arms being used in the system 300 will generally depend on the diagnostic or surgical procedure and the space constraints within the operating room, among other factors. If it is necessary to change one or more of the tools being used during a procedure, the Assistant may remove the tool no longer being used from its robotic arm, and replace it with another tool 331 from a Tray (“T”) in the operating room.

[0128] The monitor 304 may be positioned near the Surgeon's hands so that it will display a projected image that is oriented so that the Surgeon feels that he or she is actually looking directly down onto the operating site. To that end, images of the tools 338 and 339 may appear to be located substantially where the Surgeon's hands are located.

[0129] The processor 302 performs various functions in the system 300. One important function that it performs is to translate and transfer the mechanical motion of control devices 308 and 309 to their respective robotic arms 328 and 329 through control signals over bus 310 so that the Surgeon can effectively manipulate their respective tools 338 and 339. Another important function is to implement various control system processes as described herein.

[0130] Although described as a processor, it is to be appreciated that the processor 302 may be implemented in practice by any combination of hardware, software and firmware. Also, its functions as described herein may be performed by one unit, or divided up among different components, each of which may be implemented in turn by any combination of hardware, software and firmware. For additional details on robotic surgical systems, see, e.g., commonly owned U.S. Pat. No. 6,493,608 “Aspects of a Control System of a Minimally Invasive Surgical Apparatus,” and commonly owned U.S. Pat. No. 6,671,581 “Camera Referenced Control in a Minimally Invasive Surgical Apparatus,” which are hereby incorporated herein by reference in their entirety for all purposes.

[0131] FIG. 16 illustrates, as an example, a side view of a simplified (not necessarily in proportion or complete) illustrative robotic arm assembly 400 (which is representative of robotic arm assemblies 328 and 329) holding a surgical instrument 450 (which is representative of tools 338 and 339) for performing a surgical procedure. The surgical instrument 450 is removably held in tool holder 440. The arm assembly 400 is mechanically supported by a base 401, which may be part of a patient-side movable cart or affixed to the operating table or ceiling. It includes links 402 and 403 , which are coupled together and to the base 401 through setup joints 404 and 405.

[0132] The setup joints 404 and 405 in this example are passive joints that allow manual positioning of the arm 400 when their brakes are released. For example, setup joint 404 allows link 402 to be manually rotated about axis 406, and setup joint 405 allows link 403 to be manually rotated about axis 407. Although only two links and two setup joints are shown in this example, more or less of each may be used as appropriate in this and other robotic arm assemblies in conjunction with the present invention. For example, although setup joints 404 and 405 are useful for horizontal positioning of the arm 400, additional setup joints may be included and useful for limited vertical and angular positioning of the arm 400. For major vertical positioning of the arm 400, however, the arm 400 may also be slidably moved along the vertical axis of the base 401 and locked in position.

[0133] The robotic arm assembly 400 also includes three active joints driven by motors. A yaw joint 410 allows arm section 430 to rotate around an axis 461, and a pitch joint 420 allows arm section 430 to rotate about an axis perpendicular to that of axis 461 and orthogonal to the plane of the drawing. The arm section 430 is configured so that sections 431 and 432 are always parallel to each other as the pitch joint 420 is rotated by its motor. As a consequence, the instrument 450 may be controllably moved by driving the yaw and pitch motors so as to pivot about the pivot point 462, which is generally located through manual positioning of the setup joints 404 and 405 so as to be at the point of incision into the patient. In addition, an insertion gear 445 may be coupled to a linear drive mechanism (not shown) to extend or retract the instrument 450 along its axis 463.

[0134] Although each of the yaw, pitch and insertion joints or gears, 410, 420 and 445, is controlled by an individual joint or gear controller, the three controllers are controlled by a common master/slave control system so that the robotic arm assembly 400 (also referred to herein as a “slave manipulator”) may be controlled through user (e.g., surgeon) manipulation of its associated master manipulator. A more complete description of illustrative robotic surgical systems for use with the present invention can be found in commonly-assigned U.S. Pat. Nos. 9,295,524, 9,339,344, 9,358,074, and 9,452,019, the complete disclosures of which are hereby incorporated by reference in their entirety for all purposes.

[0135] Hereby, all issued patents, published patent applications, and non-patent publications that are mentioned in this specification are herein incorporated by reference in their entirety for all purposes, to the same extent as if each individual issued patent, published patent application, or non-patent publication were specifically and individually indicated to be incorporated by reference.

[0136] While several embodiments of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of presently disclosed embodiments. Thus the scope of the embodiments should be determined by the appended claims and their legal equivalents, rather than by the examples given.

[0137] Persons skilled in the art will understand that the devices and methods specifically described herein and illustrated in the accompanying drawings are non-limiting exemplary embodiments. The features illustrated or described in connection with one exemplary embodiment may be combined with the features of other embodiments. Various alternatives and modifications can be devised by those skilled in the art without departing from the disclosure. Accordingly, the present disclosure is intended to embrace all such alternatives, modifications and variances. As well, one skilled in the art will appreciate further features and advantages of the present disclosure based on the above-described embodiments. Accordingly, the present disclosure is not to be limited by what has been particularly shown and described, except as indicated by the appended claims.