U.S. patent application number 16/246010 was filed with the patent office on 2019-05-16 for hand instruments with shaped shafts for use in laparoscopic surgery.
The applicant listed for this patent is Surgiquest, Inc.. Invention is credited to Michael J. Augelli, Kurt Azarbarzin, Earl M. Zergiebel.
Application Number | 20190142498 16/246010 |
Document ID | / |
Family ID | 55861292 |
Filed Date | 2019-05-16 |
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United States Patent
Application |
20190142498 |
Kind Code |
A1 |
Zergiebel; Earl M. ; et
al. |
May 16, 2019 |
HAND INSTRUMENTS WITH SHAPED SHAFTS FOR USE IN LAPAROSCOPIC
SURGERY
Abstract
A surgical instrument for use in laparoscopic surgical
procedures is disclosed that includes an elongated shaped outer
shaft having opposed proximal and distal end portions, and having a
non-circular cross-sectional profile, an end effector operatively
associated with a distal end portion of the shaped outer shaft and
including a pair of cooperating jaw members configured for movement
between open and closed positions, a proximal handle assembly
operatively associated with a proximal end portion of the shaped
outer shaft and including a pivoting actuation handle, and an
elongated actuation member extending through the shaped outer shaft
from the proximal handle assembly to the end effector, whereby
movement of the actuation handle causes corresponding movement of
the cooperating jaw members.
Inventors: |
Zergiebel; Earl M.;
(Guilford, CT) ; Augelli; Michael J.; (Prospect,
CT) ; Azarbarzin; Kurt; (Fairfield, CT) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Surgiquest, Inc. |
Milford |
CT |
US |
|
|
Family ID: |
55861292 |
Appl. No.: |
16/246010 |
Filed: |
January 11, 2019 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
14736364 |
Jun 11, 2015 |
10201381 |
|
|
16246010 |
|
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Current U.S.
Class: |
606/52 ;
606/45 |
Current CPC
Class: |
A61B 2018/146 20130101;
A61B 18/1445 20130101; A61B 17/29 20130101; A61B 2017/293 20130101;
A61B 2018/00589 20130101; A61B 2017/2933 20130101; A61B 2017/2906
20130101; A61B 2017/2901 20130101; A61B 18/085 20130101; A61B
2017/2948 20130101; A61B 2017/2939 20130101; A61B 2018/00601
20130101; A61B 2017/2912 20130101 |
International
Class: |
A61B 18/08 20060101
A61B018/08; A61B 18/14 20060101 A61B018/14; A61B 17/29 20060101
A61B017/29 |
Claims
1-22. (canceled)
23. A surgical instrument for use in laparoscopic surgical
procedures, comprising: a) an elongated shaped outer shaft having
opposed upper wall portions that define a longitudinal gap
therebetween; b) an end effector operatively associated with a
distal end portion of the elongated shaped outer shaft and
including a pair of cooperating jaw members configured for movement
between open and closed positions; c) a proximal handle assembly
operatively associated with a proximal end portion of the elongated
shaped outer shaft and including a pivoting actuation handle; and
d) an elongated actuation ram extending through the elongated
shaped outer shaft, from the proximal handle assembly to the end
effector, wherein movement of the pivoting actuation handle causes
corresponding axial movement of the elongated actuation ram,
resulting in movement of the cooperating jaw members of the end
effector.
24. A surgical instrument as recited in claim 23, wherein the
shaped outer shaft has a non-circular transverse cross-sectional
profile.
25. A surgical instrument as recited in claim 24, wherein the
shaped outer shaft has an open square transverse cross-sectional
profile.
26. A surgical instrument as recited in claim 24, wherein the
shaped outer shaft has an open square transverse cross-sectional
profile with inwardly turned free ends.
27. A surgical instrument as recited in claim 24, wherein the
shaped outer shaft has an open square transverse cross-sectional
profile with inwardly projecting side walls.
28. A surgical instrument as recited in claim 23, wherein the
opposed upper wall portions of the shaped outer shaft are
planar.
29. A surgical instrument as recited in claim 23, wherein the
shaped outer shaft has planar lateral walls.
30. A surgical instrument as recited in claim 23, wherein the
shaped outer shaft has a planar bottom wall.
31. A surgical instrument as recited in claim 23, wherein the
actuation ram is held within the longitudinal gap defined between
the opposed upper wall portions of the outer shaft.
32. A surgical instrument as recited in claim 23, wherein the
opposed upper wall portions of the outer shaft are turned radially
inwardly into the central bore of the outer shaft.
33. A surgical instrument as recited in claim 23, wherein the
elongated shaped outer shaft has opposed lateral wall portions each
having a radially inwardly projecting medial abutment forming an
interior longitudinal gap therebetween.
34. A surgical instrument as recited in claim 33, wherein the
actuation ram is held within the interior longitudinal gap defined
between the radially inwardly projecting medial abutments.
Description
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0001] The subject invention is directed to surgical
instrumentation, and more particularly, to hand instruments with
shaped shafts for use in laparoscopic surgery performed through
pneumatically sealed trocars, rather than conventional mechanically
sealed trocars, and method of making such instruments.
2. Description of Related Art
[0002] Hand instruments for use in laparoscopic surgical procedures
are well known in the surgical arts. They are typically constructed
with an end effector provided at the distal end of an elongated
shaft that is controlled by an actuation handle associated with the
proximal end of the shaft. The end effector is designed to perform
a certain surgical task such as, for example, cutting, grasping,
ligating or retracting.
[0003] It is conventional for the shaft of a laparoscopic surgical
instrument to be circular in cross-section. This is so the
periphery of the instrument shaft can be effectively sealed within
the tubular trocar sleeve through which it passes in order to gain
access to the abdominal cavity of a patient during a laparoscopic
surgical procedure.
[0004] When a trocar having a pneumatic sealing system is employed,
such as that which is disclosed in commonly assigned U.S. Pat. No.
8,795,223, the instrument shaft does not need to be formed in a
conventional manner. That is, the instrument shaft need not have a
circular-cross-section. This opens up the design envelope for
laparoscopic instruments, allowing for differently shaped,
non-circular shafts and manufacturing methods that are not
currently used in the surgical art.
SUMMARY OF THE INVENTION
[0005] The subject invention is directed to a surgical instrument
for use in laparoscopic surgical procedures that are performed
through pneumatically sealed trocars as opposed to conventional
mechanically sealed trocars. The surgical instruments of the
subject invention include an elongated shaped outer shaft having
opposed proximal and distal end portions, and a non-circular
cross-sectional profile.
[0006] An end effector is operatively associated with a distal end
portion of the elongated outer shaft. The end effector includes a
pair of cooperating jaw members configured for movement between
open and closed positions. The instrument includes a proximal
handle assembly having a barrel portion aligned with the shaped
outer shaft, a stationary handle depending from the barrel portion,
and a pivoting actuation handle that moves relative to the
stationary handle. An elongated actuation member or ram shaft
extends through the shaped outer shaft of the instrument from the
proximal handle assembly to the end effector. In operation,
movement of the pivoting actuation handle causes corresponding
movement of the cooperating jaw members between open and closed
positions.
[0007] The distal end portion of the elongated actuation member is
operatively connected to the outer shaft by a transverse guide pin
that resides within a linear guide slot formed in the actuation
member. The distal end portion of the outer shaft includes a
bifurcated yoke section having a pair of parallel yoke arms for
accommodating the cooperating jaw members of the end effector. In
one embodiment of the invention, the cooperating jaw members are
located inside of or otherwise between the two parallel arms of the
bifurcated yoke section. In another embodiment, the cooperating jaw
members are located outside of the bifurcated yoke section, while
the actuation member extends between the two arms of the yoke
section.
[0008] A distal end portion of the actuation member is operatively
connected to the cooperating jaw members of the end effector by a
transverse cam pin. The transverse cam pin travels within linear
slots formed in the arms of the bifurcated yoke section of the
outer shaft and within an angled cam slot formed in the base of
each jaw member.
[0009] In one embodiment of the subject invention, a proximal end
portion of the actuation shaft includes a generally cylindrical
coupling for operatively connecting the actuation member or ram
shaft to the pivoting actuation handle. In another embodiment of
the subject invention, a proximal end portion of the actuation
shaft includes a pair of spaced apart flexible tabs for operatively
connecting the actuation shaft to the pivoting actuation handle.
Preferably, the proximal end portion of the actuation shaft is
cooperatively connected to an electrical contact pin or banana plug
to facilitate the performance of electro-cautery procedures.
[0010] In one embodiment of the invention, the outer shaft has a
beam shaped configuration that includes a transverse web section.
In such an instance, the actuation member or ram shaft includes a
longitudinal slot for accommodating the transverse web section of
the outer shaft. The shaped outer shaft has a beam-shaped
cross-sectional configuration that includes opposed concave lateral
supports for added structural strength and rigidity. In one
instance, the opposed concave lateral supports have a generally
rectangular configuration. In another instance, the opposed concave
lateral supports have a generally rounded configuration.
[0011] The subject invention is also directed to an articulating
surgical instrument for use in laparoscopic surgical procedures.
The instrument includes an elongated shaped outer instrument shaft
having a non-circular cross-sectional profile. The instrument
further includes an articulation coupler operatively associated
with a distal end portion of the outer instrument shaft. The
articulation coupler has a central axis and is mounted for
articulated angular movement relative to a longitudinal axis of the
elongated outer shaft. A yoke assembly or rotational coupler is
operatively associated with the articulation coupler, and an end
effector is operatively associated with the yoke assembly. The yoke
assembly or rotational coupler is mounted for axial rotation
relative to the articulation coupler. The end effector includes a
pair of cooperating jaw members that are configured for movement
between open and closed positions.
[0012] The articulating surgical instrument further includes a
proximal handle assembly having an elongated barrel portion aligned
with the shaped outer shaft, a stationary handle depending from the
barrel portion and a pivoting actuation handle mounted for movement
relative to the stationary handle. Jaw operating means are
operatively connected between the pivoting actuation handle and the
cooperating jaws of the end effector for effectuating cooperative
movement of the jaw members. In addition, articulation means are
operatively connected between the handle assembly and the
articulation coupler for effectuating articulated angular movement
of the articulation coupler relative to the longitudinal axis of
the outer instrument shaft.
[0013] In one embodiment of the subject invention, the jaw
operating means includes a relatively short distal actuation ram
extending through the yoke assembly and a relatively longer
proximal actuation ram extending from the handle assembly through
the outer shaft. A distal end of the distal actuation ram is
operatively connected to the cooperating jaw members of the end
effector by way of a transverse cam pin, and a proximal end of the
distal ram is operatively connected to the distal end of the longer
proximal actuation ram.
[0014] In another embodiment, the jaw operating means includes a
torque cable having a distal end operatively connected to a cam pin
that is operatively associated with the cooperating jaws of the end
effector and a proximal end that is operatively connected to a
cable coupler connected to the pivoting actuation handle.
[0015] In one embodiment of the invention, the articulation means
includes two actuation shafts, including a static inner actuation
shaft and a dynamic inner actuation shaft. The static actuation
shaft extends distally from the outer instrument shaft and is
pivotably connected to the articulation coupler by a first pivot
pin that is stationary. The dynamic inner actuation shaft extends
distally from the outer instrument shaft and is pivotably connected
to the articulation coupler by a second pin that moves in an angled
slot for effectuating articulated angular movement of the
articulation coupler relative to the longitudinal axis of the outer
instrument shaft. In another embodiment, the articulation means
includes an articulation cable extending through the outer
instrument shaft between an articulation coupler control knob
operatively associated with the handle assembly and the
articulation coupler at the distal end of the shaped outer
instrument shaft.
[0016] In an embodiment of the subject invention, the yoke assembly
or rotation coupler is mounted for axial rotation relative to the
articulation coupler. In this case, the handle assembly includes an
end effector rotation knob operatively connected to yoke assembly
for effectuating the axial rotation thereof relative to the
articulation coupler. In addition, the handle assembly includes an
outer shaft rotation knob operatively connected to the outer
instrument shaft for rotating the outer instrument shaft about the
longitudinal axis thereof together with the actuation member or ram
shaft.
[0017] These and other features of the subject invention and the
manner in which it is manufactured and employed will become more
readily apparent to those having ordinary skill in the art from the
following enabling description of the preferred embodiments of the
subject invention taken in conjunction with the several drawings
described below.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] So that those skilled in the art to which the subject
invention appertains will readily understand how to make and use
novel laparoscopic hand instruments the subject invention without
undue experimentation, preferred embodiments thereof will be
described in detail herein below with reference to certain figures,
wherein:
[0019] FIG. 1 is a side elevational view of a laparoscopic hand
instrument constructed in accordance with a preferred embodiment of
the subject invention;
[0020] FIG. 2 is an enlarged cross-sectional view of the barrel
portion of the handle assembly of the laparoscopic hand instrument
shown in FIG. 1, illustrating the components located herein;
[0021] FIG. 3 is an enlarged perspective view of the end effector
of the hand instrument shown in FIG. 1, with the cooperating jaws
shown in an open position;
[0022] FIG. 4 is a cross-sectional view of the shaped outer
instrument shaft and the elongated actuation ram taken through the
guide pin along line 4-4 of FIG. 3;
[0023] FIG. 5 is an exploded perspective view illustrating the
connectivity of the proximal end portion of the shaped outer shaft
and the shaft rotation knob;
[0024] FIG. 6 is an exploded perspective view of the proximal end
portion of the actuation ram with the coupler insert that connects
the actuation ram to the pivoting actuation handle;
[0025] FIGS. 7 through 10 are cross-sectional views of shaped
instrument shafts of different geometries that are configured to
resist bending and support the actuation ram;
[0026] FIG. 11 is a perspective view of another end effector which
is operatively associated with a relatively narrow shaped
instrument shaft, with the cutting jaws of the end effector in a
closed condition;
[0027] FIG. 12 is a perspective view of yet another end effector
which is operatively associated with a relatively narrow shaped
instrument shaft, with the grasping jaws in an open condition;
[0028] FIG. 13 is a perspective view of the proximal end portion of
an outer shaft separated from the barrel portion of the handle
assembly, wherein the proximal end portion of the outer shaft
includes a stamped area configured to engage a complementary
chamber in the barrel portion of the handle assembly to facilitate
shaft rotation while inhibiting axial shaft movement;
[0029] FIG. 14 is a side elevational view of the handle assembly,
in cross-section, illustrating another type of connection between
the pivoting actuation handle and the actuation ram, and wherein
the actuation ram is connected to a banana plug for electro cautery
tasks;
[0030] FIG. 15 is a perspective view of a coupling spring connected
between the proximal end of the actuation ram and the distal tip of
the banana plug associated with the handle assembly;
[0031] FIGS. 16 through 19 illustrate various embodiments of
coupling springs connected to actuation rams, as shown in FIG.
15;
[0032] FIGS. 20 and 21 are perspective views of the distal portions
of two instrument shaft assemblies constructed in accordance with
the subject invention wherein the shaft has a beam-shaped
configuration for added strength and rigidity;
[0033] FIG. 22 is a perspective view of the distal portion of yet
another shaped shaft assembly constructed in accordance with the
subject invention, wherein the actuation ram is supported on an
interior web of the beam shaped shaft;
[0034] FIG. 23 is a cross-sectional view taken along line 23-23 of
FIG. 22;
[0035] FIGS. 24 and 25 are exploded perspective views of the distal
end portions of two other shaped shaft assemblies constructed in
accordance with the subject invention, which include I-beam shaped
instrument shafts;
[0036] FIG. 26 is a perspective view of the distal end portion of a
surgical hand instrument having a shaped instrument shaft assembly
that is adapted and configured to articulate;
[0037] FIGS. 27 and 28 are side elevational views, with the wall of
the articulation coupler broken away, to illustrate the static and
dynamic actuation members of the articulation mechanism for the
instrument shaft assembly shown in FIG. 26;
[0038] FIGS. 29 and 30 are perspective views of an embodiment of
the articulating hand instrument of the subject invention that
includes an actuation cable for controlling the movement of the
jaws of the end effector;
[0039] FIG. 31 is a perspective view of a mechanism for controlling
the movement of the dynamic actuation member shown in FIGS. 27 and
28;
[0040] FIGS. 32 and 33 illustrate an articulating end effector
constructed in accordance with the subject invention;
[0041] FIGS. 34 and 35 illustrate an articulated shaped shaft
assembly constructed in accordance with the subject invention,
which includes a rotation coupled yoke assembly configured for
axial rotation relative to the articulation coupling of the shaft
assembly;
[0042] FIG. 36 is a perspective view of the handle assembly
associated with the articulated shaft assembly of FIGS. 34 and 35,
with the barrel portion in cross-section to illustrate the
components housed therein;
[0043] FIG. 37 is a more detailed cross-sectional view the handle
assembly associated with the articulated shaft assembly of FIGS. 34
and 35;
[0044] FIGS. 38 through 40 illustrate mechanisms for moving an
articulation cable, as shown in FIG. 36;
[0045] FIG. 41 illustrates a mechanism for moving two laparoscopic
instrument shafts extending from the distal end of a cannula tube
using a static control rod and a dynamic control connected by a
pivotable link; and
[0046] FIG. 42 illustrates a cammed separator mechanism for
separating to laparoscopic instruments extending from the distal
end of a cannula tube.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
[0047] Referring now to the drawings, wherein like reference
numerals identify similar structural features or aspects of the
subject invention, there is illustrated in FIG. 1 a surgical
instrument constructed in accordance with a preferred embodiment of
the subject invention and designated generally by reference numeral
10.
[0048] Referring now to FIG. 1, surgical instrument 10 is intended
for use in laparoscopic surgical procedures performed through a
pneumatically sealed surgical access device, such as that which is
disclosed, for example, in commonly assigned U.S. Pat. No.
8,795,223, the disclosure of which is herein incorporated by
reference in its entirety. This device uses a pressurized gas to
effectively seal the interface between the outer shaft of the
surgical instrument and the inner wall of the tubular trocar sheath
through which it passes instead of conventional mechanical seals,
gaskets or lubricants.
[0049] As best seen in FIG. 3, surgical instrument 10 includes an
elongated shaped outer instrument shaft 12 having opposed proximal
and distal end portions, and a non-circular cross-sectional
profile. The instrument 10 is able to be constructed with a
non-circular cross-sectional profile, rather than a conventional
circular cross-sectional profile, because it is being used with a
pneumatically sealed surgical access device, which does not require
a tight mechanical seal between the outer periphery of the shaped
instrument shaft 12 and the cylindrical inner periphery of the
trocar sheath through which is passes to access the abdominal
cavity of a patient during a surgical procedure.
[0050] An end effector 14 is operatively associated with a distal
end portion of the elongated shaped outer shaft 12. The end
effector 14 includes a pair of cooperating jaw members 16 and 18
configured for movement between open and closed positions. The end
effector 14 can be configured to perform a variety of different
surgical tasks. For example, the cooperating jaw members 16 and 18
of end effector 14 can be configured as scissors for cutting tissue
as shown in FIGS. 3 and 11, or the cooperating jaw members 16 and
18 of end effector 14 can be configured as graspers with
interlocking rows of offset teeth, as shown for example in FIG.
12.
[0051] The surgical instrument 10 also includes a proximal handle
assembly 20 having a barrel portion 22, a stationary gripping
handle 23 and pivoting actuation handle 24, which may be provided
with a ratcheted position locking mechanism (not shown). The handle
assembly 20 is ergonomically constructed so that it can be held and
operated with one hand.
[0052] Referring to FIGS. 2 and 3, an elongated ram or actuation
member 26 extends through the elongated outer shaft 12 from the
proximal handle assembly 20 to the end effector 14. As discussed in
more detail below, movement of the pivoting actuation handle 24
will cause linear movement of the actuation member 26 in either a
distal or a proximal direction, to cause corresponding movement of
the cooperating jaw members 16 and 18 between open and closed
portions. As best seen in FIGS. 3 and 4, the upper and lower
surfaces of the relatively square outer shaped shaft 12 of
instrument 10 have outwardly projecting ridges or bumps 13a, 13b
that will keep the actuation member or ram 26 properly oriented
during its proximal and distal travel.
[0053] As discussed further below, the actuation member 26 and
outer instrument shaft 12 are adapted and configured to axially
rotate together. In this regard, the outer shaft 12 includes a pair
of proximally extending bent tabs 15 and 17 shown in FIG. 5, which
reside in an annular channel 19 formed in the barrel portion 22 of
the handle assembly 20, as seen in FIG. 2. This engagement
restricts the linear movement of the outer shaft 12 relative to the
handle assembly 20, while permitting axial rotation of the outer
shaft 12 about its axis relative to the handle assembly 20.
[0054] The actuation shaft or ram 26 has a generally rectangular
cross-sectional configuration and is well suited for use with a
variety of different shaped instrument shafts. Examples of a
variety of shaped instrument shafts are shown in FIGS. 7 through
10. In each instance, the shaped outer instrument shaft would be
covered with heat shrink tubing that would fully conform to the
shape of the shaft, as shown for example in FIG. 3.
[0055] A shaped outer instrument shaft 12a having a fully closed
square cross-sectional profile is shown in FIG. 7. A shaped outer
shaft 12b that has an open square cross-sectional profile is shown
in FIG. 8. A shaped outer shaft 12c that has an open square
cross-sectional profile with inwardly turned free ends is shown in
FIG. 9, and a shaped outer shaft 12d that has an opened square
cross-sectional profile and inwardly projecting side walls is shown
in FIG. 10. The shaped outer shafts 12b-12d of FIGS. 8 through 10,
respectively, are designed to isolate and hold the actuation ram 26
extending therethrough.
[0056] Those skilled in the art will readily appreciate that an
instrument shaft having a square shape will have equal resistance
to bending from side to side or corner to corner. It should also be
appreciated that there are manufacturing advantages associated with
having a shaped instrument shaft as described herein, in that the
shaft can be stamped from a flat sheet of metal with all of the
necessary slots and apertures for pins and rivets provided therein
and then subsequently bent or otherwise formed into a final shape.
It is also envisioned that the shaped instrument shaft of the
subject invention could be extruded or injection molded with
internal features such as lumens.
[0057] It is further envisioned that the outer instrument shaft 12
can be formed in a relatively narrow configuration so that the
width-wise dimension of the shaped shaft is less than the
height-wise dimension of the shaped shaft, as shown for example in
FIGS. 11 and 12. In such instances, the actuation member or ram 26
will be more intimately enclosed within the shaped instrument shaft
12, providing greater structural stability to the actuation member
26 so as to inhibit bending. Those skilled in the art will readily
appreciate that a thin rectangular structure will inhibit bending
more in the longer side of the rectangle than on the shorter side
of the rectangle.
[0058] Referring now to FIG. 3, the distal end portion of the
actuation member 26 is operatively connected to the outer
instrument shaft 12 by a transverse guide pin 28 that resides
within a linear guide slot 30 formed in the actuation member 26.
This engagement is also shown in 4. The distal end portion of the
outer shaft 12 includes a bifurcated yoke section 32 with two
parallel yoke arms 32a, 32b for accommodating the cooperating jaw
members 16 and 18 of the end effector 14. The cooperating jaws 16
and 18 are pivotably connected to the arms of the yoke 32 by a
transverse yoke pin 34.
[0059] The distal end portion of the actuation member or ram 26 is
also operatively connected to the cooperating jaw members 16 and 18
of the end effector by a transverse cam pin 36. The transverse cam
pin 36 travels within linear cam slots 38 formed in each arm of the
bifurcated yoke section 32 of the outer shaft 12 and within
oppositely angled cam slots in 40 and 42 each of the jaw members 16
and 18, respectively. Preferably, the cam pin 36 is press fit into
the distal end portion of the actuation member 26 and it has a
clearance fit within the angled jaw member cam slots 40 and 42 and
the linear cam slots 38 in the yoke section 32.
[0060] As best seen in FIG. 5, the proximal end portion of the
outer shaft 12 is operatively associated with a shaft rotation knob
33 that is supported in the barrel portion 22 of the proximal
handle assembly 20 (see FIGS. 1 and 2). More particularly, the knob
33 is mounted to effectuate axial rotation of the outer instrument
shaft 12 together with the actuation shaft 26 about the
longitudinal axis thereof. The knob 33 includes a central lobed
aperture 35 for cooperatively engagement with the outer shaft 12.
To assemble this feature, the lobed aperture 35 in knob 33 is
aligned with the proximal bent tabs 15 and 17 located on the
proximal end of the outer shaft 12, and the knob 33 is then placed
over the end of the outer shaft 12. Thereafter, the knob 33 is
rotated 90 degrees to lock the outer shaft 12 into the lobed
aperture 35.
[0061] Referring to FIG. 6, in one embodiment of the subject
invention, a proximal end portion of the actuation member 26
includes a two-part symmetrical coupling 44a, 44b for operatively
connecting the actuation member 26 to the pivoting actuation handle
24. When the two couplers 44a, 44b are used together and facing one
another, they will fit and hold together through a plurality of
symmetrically placed holes and posts, as shown. An engagement tab
45 extends from the inner surface of each coupler 44a, 44b for
engaging a linear slot 47 formed in the proximal portion of
actuation shaft 26. The linear slot 47 is longer than the
individual tabs 45 because both tabs are engaged with the slot 47.
Moreover, as best seen in FIG. 2, the symmetric couplers 44a, 44b
are accommodated within a cylindrical chamber 49 formed in the
barrel portion of the handle assembly 20. The two couplers 44a, 44b
will move axially and rotationally within the chamber 49 in the
barrel portion 22 of handle assembly 20, as best seen in FIG.
2.
[0062] With continuing reference to FIG. 6 in conjunction with FIG.
2, the actuation handle 24 has a keyhole feature 57, which includes
a larger diameter portion configured for assembly over the larger
diameter of the coupler 44a, 44b. Once over the larger diameter
portion of the coupler, the smaller diameter area of the keyhole
feature 57 will mate with the smaller outside diameter portion of
the coupler, as shown in FIG. 2. When the actuation handle 24 is
pivoted, it will move the couplers 44a, 44b which will move the
actuation shaft 26 to actuate the jaws of the end effector 14.
[0063] Referring to FIG. 13, there is illustrated another manner of
constraining the outer instrument shaft 12 within the barrel
portion 22 of the proximal handle assembly 20. More particularly,
an elongated notch is 39 is stamped and formed into the proximal
end portion of the outer shaft 12 which is arranged within a cavity
29 formed in the barrel portion 22 so that it will not move
linearly relative to the handle assembly 20 but it can still rotate
axially with respect to the barrel portion of the handle assembly
20.
[0064] In one embodiment of the subject invention, the cooperating
jaw members 16 and 18 are located inside of the arms of the
bifurcated arms 32a, 32b or yoke section of instrument shaft 12, as
shown for example in FIG. 20. In another embodiment of the subject
invention, the cooperating jaw members 16 and 18 are located
outside of the bifurcated arms 32a, 32b of the yoke section of the
instrument shaft 12. It is envisioned that a biasing washer could
be placed on the end effector pivot/yoke pin 34 between the
cooperating jaw members 16 and 18 or between the arms of yoke
section 32 and the jaw members 16 and 18 of the end effector 14 to
more effectively tolerance the fit of the jaws members.
[0065] Referring once again to FIG. 2 in conjunction with FIG. 5,
the proximal end portion of the actuation member 26 is
cooperatively connected to a hollow banana plug-type electrical
contact pin 50 for electro-cautery tasks. The banana plug or
contact pin 50 is supported within the barrel portion 22 of the
handle assembly 20 and is positioned over a pair of elongated
flexible tabs 55a, 55b that project from the proximal end of
actuation shaft 26. When the flexible tabs 55a, 55b are positioned
with the interior bore 52 of the plug 50, the actuation shaft 26 is
able to move linearly and rotationally without disengaging from the
plug 50 so as to maintain constant electro-cautery
connectivity.
[0066] Referring now to FIG. 14, there is illustrated another way
to connect the proximal end portion of actuation member or ram 26
to the pivoting actuation handle 24. In this case, flexible finger
tabs 57a, 57b are stamped into the proximal portion of the
actuation ram 26 which also has an undercut on the outer face
thereof. The flexible tabs 57a, 57b are squeezed together to fit
into a hole in the actuation handle 24 and then the undercut on the
outer face of the actuation ram 26 outer face engages both sides of
the actuation handle 24. When the handle 24 is pivoted or otherwise
rotated, the actuation ram 26 will move linearly.
[0067] Proximal and distal washers 59a and 59b can be added to help
increase the surface area of contact between the actuation handle
24 and the actuation ram 26 for a more robust fit. Also shown in
FIG. 14 is another way to facilitate cooperative engagement between
the actuation ram 26 and the banana plug 50. In this case, a small
diameter post 54 on the plug 50 extends between the flexible tabs
57a, 57b of the actuation ram 26. This arrangement allows constant
electrical contact between the two components, while the actuation
ram 26 moves both linearly and rotationally.
[0068] Referring to FIG. 15, there is shown an alternative way of
mechanically and electrically connecting the proximal end portion
of the actuation ram 26 to a banana plug 50, using a leaf spring
56. More particularly, the hooked distal end 53a of the leaf spring
56 is mechanically connected to the proximal end of the actuation
member 26, while the hooked proximal end 53b of the leaf spring 56
is in biased contact with the distal post 54 of the contact pin 50.
Again, the electrical contact pin 50 is adapted and configured to
be connected to a source of electrical energy, so that the end
effector can be used to cauterize tissue during a surgical
procedure. FIGS. 16 through 19 illustrate several different
embodiments of leaf springs for mechanically and electrically
connecting the proximal end portion of the actuation member 26 to
the electrical contact pin 50. These include leaf springs 56a-56d,
as shown.
[0069] Referring now to FIGS. 20-25, in certain embodiments of the
subject invention, the shaped outer shaft 12 of the instrument has
a beam shaped configuration that includes a transverse central web
section 66. One example is shown for example in FIGS. 22 and 23. In
such an instance, the actuation member 26 includes a longitudinal
slot 68 for accommodating the transverse web section 66 of the
outer shaft 12, as shown in FIG. 23.
[0070] In an embodiment of the subject invention, the outer shaft
12 of the instrument 10 has a beam-type geometric configuration
that includes opposed concave lateral supports 70a and 70b. In one
instance, the opposed concave lateral supports 70a and 70b have a
generally rectangular configuration, as shown in FIG. 21. In
another instance, the opposed concave lateral supports 70a and 70b
have a generally rounded configuration, as shown in FIG. 20. These
beam-shaped outer shaft designs, which curve or bend away from the
actuation ram 26, have a high resistance to bending in any
direction. As further illustrated in FIG. 21, the pivot/yoke pin 34
associated with the cooperating jaws member 16 and 18 of the end
effector 14 can take the form of a shoulder type rivet or the pin
34 could be constructed as a double rivet or two rivets inserted
into a hollow central tube.
[0071] Referring now to FIGS. 24 and 25, there is illustrated two
additional mechanical constructs of a beam shaped shaft 80
configured in accordance with the subject invention. The mechanical
construct of FIG. 24 includes an elongated U-shaped actuation
member 82 for controlling the movement of distal end effector s 84
and 86 using an actuation handle 88. The elongated "U" shaped
actuation member 82 surrounds the central web of the beam shaped
instrument shaft 80. The mechanical construct of FIG. 25 includes
upper and lower rectangular actuation sleeves 94 and 96 that
interlock with the upper and lower supports of the beam shaped
instrument shaft 80. The upper and lower actuation sleeves 94 and
96 control the respective movement of corresponding distal end
effectors 84 and 86.
[0072] Referring now to FIGS. 26 through 30, there is illustrated
another surgical instrument 100 having a non-circular,
substantially square outer instrument shaft which is configured
with an articulating and rotating distal end portion for enhancing
the operational range of movement of the device during laparoscopic
surgical procedures.
[0073] Referring to FIGS. 26-28, there is illustrated an
articulating surgical instrument 100 constructed in accordance with
a preferred embodiment of the subject that includes an elongated
outer shaped instrument shaft 112 having opposed proximal and
distal end portions, and a non-circular cross-sectional profile.
The surgical instrument 100 includes an articulation coupler 114
operatively associated with a distal end portion of the outer
instrument shaft 112. The articulation coupler 114 has a central
axis and is mounted for articulated angular movement relative to a
longitudinal axis of the elongated outer shaft 112. More
particularly, the articulating coupler 114 is mounted to pivot 90
degrees relative to the longitudinal axis of the outer instrument
shaft 112.
[0074] A yoke assembly 116 is operatively associated with the
articulation coupler 114, and an end effector 118 is operatively
associated with the yoke assembly 116. The end effector 118
includes a pair of cooperating jaw members 120 and 122 configured
for movement between open and closed positions.
[0075] In an embodiment of the subject invention shown in FIGS.
26-28, the articulation means includes a static inner actuation
shaft 170 extending distally from the outer instrument shaft 112
and pivotably connected to the articulation coupler 114 by a pin
115, and a dynamic inner actuation shaft 172 extending distally
from the outer instrument shaft 112 and pivotably connected to the
articulation coupler 114 by a pin 117 through an angled slot 119
for effectuating articulated angular movement of the articulation
coupler 114 relative to the longitudinal axis of the outer
instrument shaft 112.
[0076] Referring to FIGS. 36 and 37, the surgical instrument 100
further includes a proximal handle assembly 125 having a barrel
portion 123, stationary handle 126 and a pivoting actuation handle
128. Jaw operating means, which are described in greater detail
below, are operatively connected between the pivoting actuation
handle 128 and the cooperating jaws members 120 and 122 of the end
effector 118 for effectuating cooperative movement of the jaw
members 120 and 122. In addition, articulation means, which are
also described in more detail below, are operatively connected
between the handle assembly 125 and the articulation coupler 114
for effectuating articulated angular movement of the articulation
coupler 114 or yoke assembly 116 relative to the longitudinal axis
of the outer instrument shaft 112.
[0077] In one embodiment of the subject invention shown in FIGS. 26
and 33, the jaw operating means includes a relatively short distal
actuation ram 130 extending through the yoke assembly 116. A distal
end of the distal actuation ram 130 is operatively connected to the
cooperating jaw members 120 and 122 of the end effector 118 by a
cam pin. The proximal end of the distal actuation ram 130 is
operatively connected to a longer actuation ram 132 that extends
through the outer shaft from the handle assembly. That is the jaw
operating means also includes a relatively long proximal actuation
ram 132 extending through the elongated outer instrument shaft 112
from the proximal handle assembly 125 to the yoke assembly 116.
[0078] A proximal end of the proximal actuation ram 132 is
operatively connected to the pivoting actuation handle 128. The
short actuation ram 130 could also be connected to a torque cable,
or to a nut that runs along a lead screw. Furthermore, it is
envisioned that the shorter distal ram could connect to the
proximal longer ram or to a torque cable. This connection could be
made with a ball joint (not shown) or a universal joint (also not
shown).
[0079] In another embodiment shown in FIGS. 29 and 30, the jaw
operating means includes a flexible torque cable 160 for
controlling the end effector 118. The torques cable 160 has a
distal end grommet 162 operatively connected to a cam pin 165 that
is operatively associated with the cooperating jaws 120 and 122 of
the end effector 118. A proximal end of the torque cable 160 is
operatively connected to a cable coupler 185 connected to the
pivoting actuation handle 128, as best seen in FIG. 37. The torque
cable 160 allows the articulation coupler 114 to move 90 degrees
and still transmit both a rotational element to the end effector
118 and a linear movement to open and close the jaws 120 and 122 of
the end effector 118.
[0080] Referring to FIG. 31, there is shown a way to move the
dynamic inner actuation shaft 170 shown in FIGS. 26 through 30.
That is, double non-coaxial discs 175, 177 form a knob at the
proximal end of the instrument. The smaller non-coaxial disc 175
engages notches 179 in the proximal end of the dynamic inner
actuation shaft 170. As the user rotates the disc 175, 177, the
dynamic inner actuation shaft 170 will move linearly and distally,
thereby articulating the distal end portion of the instrument.
[0081] FIG. 33 shows an alternate way to open and close the jaw
members 120 and 122 of end effector 118. In this case a retainer
ring 190 and spring 192 within the rotating yoke assembly or
coupler 116 biases the actuation ram 196 to a fully distal
position, keeping the end effector jaws 120 and 122 in an open
state. As the user squeezes the actuation handle 128, the actuation
ram 196 or a torque cable will move distally and close the end
effector 118. Releasing tension on the handle 128 will let the
distal spring 192 automatically open up the end effector 118.
[0082] Referring to FIGS. 34 through 36, there is shown an
embodiment of the subject invention wherein the articulation means
includes a looped articulation coupler cable extending through the
outer instrument shaft 212, between an articulation coupler control
knob 182 associated with the handle assembly 125 and the
articulation coupler 214. In this embodiment, the outer instrument
shaft 212 is either an extrusion or an injection molded structure
and it has multiple full length inner lumens formed therein. The
center lumen 220 is dimensioned for either a torque cable 260 or a
long actuation ram, as shown for example in FIG. 32. The outer
lumens 222 on either side of the center lumen 220 accommodate
cables 224 to activate the articulation coupler 214. The pivot
point 228 is provided for the articulation coupler 214. The
articulation coupler 214 extends into the rotation coupler 216 and
is held in place with the use of retaining rings 230 or C-shaped
clips.
[0083] Referring to FIGS. 36 and 37, the yoke assembly or
rotational coupler 216 is mounted for rotation relative to the
articulation coupler 214, as depicted in FIG. 34. In this case, the
handle assembly 125 includes an end effector rotation knob 184
operatively connected to rotational coupler 216 for effectuating
the axial rotation thereof relative to the articulation coupler
214. The actuation handle 128 will open and close the end effectors
118. This is done via a torque cable coupler 185, wherein the
torque cable 260 is inserted inside the coupler and crimped
proximally. The actuation handle fits over the torque cable 185
coupler similar to the symmetrical coupler previously already
disclosed.
[0084] The torque cable coupler 185 also has flats 187 on its
outside to mate with the end effector knob 184. By rotating the end
effector knob 184 the torque cable coupler 185 rotates, which will
rotate the torque cable 260. A feature can be added to the crimp
area to help rotation (not shown).
[0085] In addition, as best seen in FIGS. 36 and 37, the handle
assembly 125 includes an outer shaft knob 186 operatively connected
to the outer instrument shaft 212 for rotating the outer instrument
shaft 212 about the longitudinal axis thereof. The handle assembly
125 also includes an articulation knob 182 that holds the proximal
ends of the articulation cables 224 which extend from the
articulation coupler 214 and pivot within the shaft rotation knob
186. As the articulation knob 182 is rotated, the cables 224 get
pulled proximally and activate the articulation coupler 214. The
shaft rotation knob 186 fits to the outer shaft 212 via grooves and
flats. When it is rotated along with the articulation knob 182, the
cables 224 do not twist.
[0086] Referring to FIGS. 38 through 39, there is illustrated a
mechanical construct depicting how the articulation coupler cable
224 is arranged to effectuate articulation of the articulation
coupler 214. In this construct, the cable 224 is connected between
the distal articulation coupler 214 and the proximal articulation
coupler knob 182 such that one side of the looped cable 224 is
pulled proximally under tension, and the opposite side of the
looped cable 224 will slacken to allow articulation.
[0087] FIG. 40 shows another way to connect the proximal ends of
the articulation cable 224 to the articulation coupler knob 182 in
a configuration that resembles a boat rigging design, wherein the
looped cable 224 is wrapped around a knob 182. By rotating the knob
182, the cable 224 will activate the articulation coupler 214.
[0088] Referring now to FIGS. 41 and 42, there are illustrated two
different ways in which two jawed instruments 312 and 314 can be
inserted into a cannula tube 316 and used together in a procedure.
In such instances, the jawed instruments 312 and 314 are separated
from one another at the distal tip of the cannula tube 316. For
example, in FIG. 41, the static inner shaft 322 is pinned or
riveted to the holder 324 and the holder 324 pivots at this
feature. The dynamic inner shaft 326 is also pinned or riveted to
the holder 324. As the dynamic inner shaft 326 is moved linearly it
will cause the holder 324 to rotate around its fixed, static pivot
point. The two instruments 312 and 314 would be inserted into
respective slots 332 and 334 on either end of the holder 324.
Depending on how the holder 324 is pivoted, the two instruments 312
and 314 would either come together or be separated.
[0089] A cam operated separator 350 is shown in FIG. 41. In this
case, after insertion by the user, the ramped or lobed separator
350 can be linearly extended beyond the outer cannula tube 316
using an elongated rod 352. There are two ramps or cam features on
the separator 350. The two instruments 312 and 314 can be extended
beyond the separator 350 and they will separate away from each
other after moving against the separator ramps, like cam features.
The separator 350 could include scallops so that as the two
instruments 312 and 314 extend past the separator 350 within one
set of scallops. The separator 350 would be rotated 90 degrees
until the second set of scallops engage the two instruments 312 and
314 and separate them.
[0090] While the laparoscopic hand instruments of the subject
invention have been shown and described with reference to several
preferred embodiments, those skilled in the art will readily
appreciate that various changes and/or modifications may be made
thereto without departing from the spirit and scope of the subject
invention as defined by the appended claims.
* * * * *