System for suturing

Abstract

Embodiments disclosed herein include systems for suturing wounds, incisions, or other openings. The system includes a helical needle having a radius, the needle having a tip at a first end of a shaft and a filament joined to a second end; a roller mechanism comprising a first roller and a second roller supporting a substantially parallel configuration, the first roller and the second roller being configured to engage a shaft of the needle therebetween, the needle being rotatable about the first roller, where the first roller has a roller radius smaller than a radius of the helical needle, and the second roller having a roller radius smaller than a radius of the helical needle. A second roller disposed adjacent to the first roller to enable the first end of the needle to pierce the body and draw the filament through the body disposed adjacent to the first roller, and the second roller having a surface defining a groove therein, the groove configured to at least partially receive a shaft of the needle; and a motor drive including a motor and an interaction device configured to enable the motor drive to be supported by one of the human user and the robotic actuator.

Description

[0001] This application is a divisional application of the invention patent application No. 202110341879.6, titled "Devices and Systems for Suturing", filed on March 30, 2021.

[0002] Priority Statement

[0003] This patent application claims the priority and benefits of U.S. Provisional Patent Application Serial Nos. 63 / 002,928 and 63 / 002,995, both titled "MOVABLE SUTURING APPARATUS AND METHOD", filed on March 31, 2020. Technical Field

[0004] The present disclosure relates to devices, systems, and methods for suturing an object. Background Art

[0005] The description in this section provides only background information related to the present disclosure and may not constitute prior art.

[0006] Suturing is commonly used to close incisions or wounds. Sutures are typically formed by passing a curved needle through tissue on both sides of an incision or wound, where the needle pulls a filament from a rear end. Once the curved needle has completed a full rotation around the incision or wound, the filament forms a suture to hold the tissue closed.

[0007] Although the process itself is well known, the process of positioning the needle at a desired location and actuating the needle may not be straightforward. Even when suturing is performed by a technician and / or an experienced healthcare provider, the person suturing the wound or incision may have difficulty reaching the location and actuating the needle through the tissue. Summary of the Invention

[0008] The embodiments disclosed herein include devices, systems, and methods for suturing a wound, incision, or other opening.

[0009] In an exemplary embodiment, the device includes a roller mechanism configured to rotatably support two generally parallel rollers in a reversible manner, the two generally parallel rollers being configured to engage the shaft of a helical needle therebetween, the needle having a tip at a leading end, pulling a filament from a rear end, and having a first helical radius, the needle being capable of rotating around a first roller, the roller radius of the first roller being less than the helical radius of the needle, such that the needle can pierce the body and pull the filament through the body disposed adjacent to the first roller. A motor driver is operably coupled to the roller mechanism to transmit a rotational force to rotate the two generally parallel rollers. A controller is operably coupled to the motor driver and is configured to cause the needle to complete at least one rotation to form a single suture in the body.

[0010] In another embodiment, the system includes a helical needle having a helical radius, the needle having a tip at a first end of the shaft and a filament coupled to the second end. A roller mechanism is configured to rotatably support two substantially parallel rollers, the two substantially parallel rollers being configured to engage the shaft of the needle therebetween, the needle being capable of rotating about the first roller, the roller radius of the first roller being less than the helical radius of the needle, such that the first end of the needle can pierce the body and draw the filament through the body disposed adjacent the first roller. A motor driver includes a motor and a controller, the motor being operably coupled to the roller mechanism to transmit a rotational force to rotate the two substantially parallel rollers, the controller being operably coupled to the motor and configured to cause the needle to complete at least one rotation to form a single suture in the body.

[0011] In another embodiment, in an exemplary method, a first one of two substantially parallel rollers is positioned adjacent the body, where the two substantially parallel rollers engage a helical needle therebetween, where the needle draws a filament from a rear end, has a first helical radius greater than the radius of the first roller, and is capable of rotating about the first roller such that the needle can pierce and extend through the body. An input is provided to a motor that is operably coupled to at least one of the two substantially parallel rollers, where the input causes the motor to rotate to rotate the two substantially parallel rollers to cause the needle to complete at least one rotation to form a single suture.

[0012] In a further exemplary embodiment, the device includes a helical needle having a first helical radius, the needle having a shaft and drawing a filament from a rear end. Two substantially parallel rollers are configured to engage the shaft of the needle therebetween, a first roller having a roller radius less than the helical radius of the needle such that the needle can rotate about the first roller to pierce the body disposed adjacent the first roller and draw the filament through the body. A frame is configured to rotatably support the rollers. The frame includes a support coupling and a drive coupling, the support coupling being configured to removably receive a distal end of a support shaft extending from a drive mechanism, the drive coupling being configured to removably receive a distal end of a drive member extending from the drive mechanism, the drive member being configured to provide a rotational force to at least one of the rollers.

[0013] In another illustrative embodiment, the drive mechanism includes a housing, a motor supported by the housing, a support shaft extending from the housing, and a drive member coupled to the motor and supported by the shaft, wherein the drive member is configured to transmit a rotational force from the motor. The suture bobbin includes a helical needle having a first helical radius, the needle having a shaft and pulling a filament from a rear end. Two generally parallel rollers are configured to engage the shaft of the needle therebetween, the first roller having a roller radius less than the helical radius of the needle to enable the needle to rotate about the first roller to pierce a body disposed adjacent the first roller and pull the filament through the body. The frame is configured to rotatably support the rollers reversibly. The frame includes a support coupling and a drive coupling, the support coupling being configured to removably receive a distal end of the support shaft, the drive coupling being configured to removably receive a distal end of the drive member and transmit a rotational force to at least one of the rollers.

[0014] In another embodiment, an exemplary method includes engaging a suture bobbin with a motor driver. The suture bobbin supports a pair of generally parallel rollers that rotatably engage the shaft of a helical needle therebetween, the needle being rotatable about a first roller and having a helical radius greater than the roller radius of the first roller to enable the needle to pierce and extend through a body disposed adjacent the first roller. A first of the two generally parallel rollers is positioned adjacent the body. An input is provided to the motor driver, wherein the input causes the motor driver to rotate and the two generally parallel rollers to rotate so that the needle completes at least one rotation to form a single suture.

[0015] Based on the description provided herein, other features, advantages, and applicable fields will become apparent. It should be understood that the specific embodiments and specific examples are only for illustrative purposes and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF THE DRAWINGS

[0016] The drawings described herein are for illustrative purposes only and are not intended to limit the scope of the present disclosure in any way. The components in the drawings are not necessarily drawn to scale, but rather the emphasis is placed on illustrating the principles of the disclosed embodiments. In the drawings:

[0017] Figure 1 is a perspective view of an embodiment of a device for suturing an object;

[0018] Figure 2 is Figure 1 a perspective view of a roller mechanism of the device;

[0019] Figure 3 is Figure 1 a schematic block diagram of components of the device;

[0020] Figure 4A and Figure 4Bis a device positioned to sew an object with a human hand and a robotic actuator, respectively Figure 1 Perspective view of the device;

[0021] Figure 5 is a side view of a helical needle that can be used with the Figure 1 device;

[0022] Figure 6 is Figure 5 Cross-sectional view of the needle;

[0023] Figure 7 is a side view of a needle engaged with a roller of the Figure 1 and Figure 2 device; Figure 5 Side view of the needle;

[0024] Figure 8 is a top view of a portion of a needle received in a groove of one of the rollers of the Figure 7 roller; Figure 5 Top view of the portion of the needle;

[0025] Figure 9 is a side view of a needle received in a roller with an expanded groove Figure 5 Side view of the needle;

[0026] Figure 10 is a schematic view of a roller of a device that engages a needle subjected to a lateral force of a compression needle Figure 7 Schematic view of the roller;

[0027] Figures 11 to 13 is a schematic view of a roller of a device that receives a needle in a correction recess Figure 7 Schematic view of the roller;

[0028] Figures 14 to 16 Side view of a needle received by a correction recess and guided into a groove;

[0029] Figure 17 and Figure 18 are schematic views of a grooved roller of a device that employs correction recesses of other shapes Figure 7 Schematic view of the grooved roller;

[0030] Figure 19A and Figure 19B are schematic axial views of a needle that may miss a correction recess on a grooved roller;

[0031] Figure 20A and Figure 20B are schematic axial views of a needle with a reduced helical radius;

[0032] Figure 21A and Figure 21B are needles that impact the surface of a grooved roller and are then received in a correction recess Figure 20A and Figure 20BSchematic view of a needle;

[0033] Figure 22 is of a device using a removable suture bobbin Figure 1 Perspective view of the shaft of the device;

[0034] Figure 23 is of a shaft of a device that can be engaged with an alternative suture bobbin having needles of different sizes Figure 1 Perspective view of the shaft of the device;

[0035] Figure 24 is a top view of a supply tray that supports the motor drive of the device and a plurality of interchangeable suture bobbins; Figure 1

[0036] Figure 25 is a side view of a portion of a supply tray that supports interchangeable suture bobbins; Figure 24

[0037] Figure 26A is a schematic view of a helical needle positioned to suture an opening;

[0038] Figure 26B is Figure 26B schematic view of the helical needle after it has rotated to suture the opening;

[0039] Figure 27 is a flowchart of an exemplary method of suturing a body using a helical needle actuated by two generally parallel rollers; and

[0040] Figure 28 is a flowchart of an exemplary method of engaging a suture bobbin with a motor drive to suture a body. DETAILED DESCRIPTION

[0041] The following description explains, by way of illustration and not limitation, various embodiments of devices, systems, and methods for suturing an opening (such as a wound or incision) in a body. It should be noted that the first digit of a three - digit reference number and the first two digits of a four - digit reference number correspond to the figure number in which the element first appears.

[0042] ​​By way of non - limiting introduction and overview, the devices and systems of the present disclosure employ a motor driver to actuate two generally parallel rollers that engage opposite faces of a shaft that engages a helical needle. The first of the two rollers is disposed adjacent to an opening in a body (such as a wound or incision). The helical needle and the first roller are sized such that the helical needle can rotate about the first roller and pass through tissue on the opposite side of the opening. The rear end of the helical needle pulls a filament. When the motor driver causes the rollers to rotate the needle through one complete rotation, a suture is formed to close the opening. In various embodiments, the motor driver has a controller that causes the motor to form a single suture when a button is pressed or another discrete input is received. Thus, by positioning the rollers and the needle at the desired suture location and providing a single input, a suture can be formed without the need for an operator or actuator to move to manually pull the needle through the body to form the suture.

[0043] In various embodiments, the motor driver is capable of detachably engaging a suture cartridge that supports the rollers and the needle. Thus, different cartridges can be detachably and disposable engaged by the motor driver to form sutures on different parts of a body or on different bodies. The motor driver can be reused while the suture cartridge, including the rollers and the needle, can be discarded. Additionally, alternative suture cartridges can support needles of different sizes to support the formation of different sized sutures for different applications.

[0044] Now that an overview has been given, the details of the various embodiments will be explained by way of non - limiting examples given by way of illustration only and not by way of limitation.

[0045] Additionally referring Figure 1 , in device 100 includes a motor driver 120 coupled to a roller mechanism 150 that actuates a helical needle 180 that pulls a filament 190 to form a suture ( Figure 1 not shown in). The motor driver 120 includes a housing 122 that supports and / or contains other components of the motor driver 120. The housing 122 includes an interface device 124 that facilitates the housing 122 being gripped by a human operator or supported by a robotic arm or other mechanical actuator ( Figure 1 not shown in). The interface device 124 can be shaped or textured to assist an operator or actuator in being able to firmly hold the housing 122.

[0046] The housing 122 can support one or more controls 124 and 126 that control the operation of the motor driver 122. In various embodiments, and as further described below, a suture control 124 can cause components of the motor driver 120 to rotate the needle 180 through one rotation to form a single suture. A second control 126 can be configured to stop and / or reverse the rotation of the needle 180 as needed. An electrical input 128 can be included to allow power to be supplied from an external source (not shown) to the motor and other components ( Figure 1(not shown in the figure) provides power. Instead of or in addition to controls 124 and 126, electrical input terminal 128 can also be used to provide an input signal. For example, using such an input terminal 128 can allow a human operator to trigger the formation of a suture by activating a foot switch (not shown) or other external controls. Additionally, if device 100 is used by a robotic arm or other actuator, input terminal 128 can allow the actuator to control device 100 without physically engaging controls 124 and 126.

[0047] In various embodiments, shaft 130 extends from housing 122 to support roller mechanism 150. The size and shape of shaft 130 can be configured to allow roller mechanism 150 to be conveniently positioned away from housing 122 to form a suture without housing 122 and / or the operator's hand or other support body being placed close to the opening to be sutured. Thus, the distance between housing 122 and roller mechanism 150 can provide the operator with greater visibility of the opening to be sutured and provide additional degrees of freedom of movement compared to the case where housing 122 must be adjacent to the opening to be sutured. Shaft 130 can mechanically support roller mechanism 150 and accommodate a drive member ( Figure 1 (not shown in the figure), as further described below.

[0048] Additionally referring to Figure 2 , roller mechanism 150 can include a frame 154 that supports rollers 156 and 158, which actuates needles 180 that in turn pull filaments 190 to form a suture. As further described below, frame 154 can be detachably coupled to shaft 130. The proximal end 152 of frame 150 can engage the distal end 132 of shaft 130. The aforementioned drive coupling (not shown) can extend across and / or through the junction of the distal end 132 of shaft 130 and the proximal end 152 of the frame to provide a rotational force to rollers 156 and 158.

[0049] First roller 156 can be positioned adjacent to an opening in the body to be sutured ( Figure 1 and Figure 2 (not shown in the figure), where helical needle 180 is positioned to orbit around first roller 156 to pierce the body and pull filament 190 therethrough. The shaft of needle 180 is engaged by first roller 156 and a second roller on opposite sides, and rollers 156 and 158 rotate in opposite directions to cause needle 180 to eccentrically rotate around first roller 156. As further described below, second roller 158 can include a groove 159 to partially receive needle 180 to position and fix the needle as it rotates to form a suture. The open end 160 of frame 150 enables filament 190 to be pulled by needle 180 without filament 190 being guided or potentially blocked by the frame at open end 160.

[0050] Additionally referring to Figure 3, in various embodiments, the motor driver 110 includes components that support the aforementioned functions. As previously described, the motor driver 110 includes a stitching control 124, a second control 126, and an electrical input 128. In such embodiments, the motor driver 110 may also include a motor 310, a controller 320, a power source 330, and a drive member 340.

[0051] In various embodiments, the motor 310 is any type of electric motor that provides a selectively activatable source of rotational force that is transmitted to the roller mechanism 150. The motor 310 is mechanically coupled to a drive member 340, such as a drive shaft or a drive cable. As further described below, the drive member 340 is capable of being operatively coupled to a drive coupling 350 of the roller mechanism 150. The drive member 340 (which may be a drive shaft or a drive cable that is mechanically coupled to at least one of the rollers 156 or 158) receives rotational force from the motor 310 via the drive member 340 and the drive coupling 350 to rotate at least one of the rollers 156 and 158 to actuate the needle 180 to form a stitch, as further described below.

[0052] In various embodiments, the motor 310 is coupled to the controller 320, which in various embodiments is coupled to the stitching control 124, the second control 126, the electrical input 128, and the power source 330. In various embodiments, the controller 320 is a logic circuit or a microprocessor that can be configured to direct the operation of the motor 310 when receiving control inputs received from the stitching control 124, the second control 126, and / or the electrical input 128. As previously described, when the user engages the stitching control 124 (or receives a similar instruction via the electrical input 128), the controller 320 causes the motor 310 to rotate to turn the roller mechanism 150 to rotate the needle 180 ( Figure 1 and Figure 2 ) to complete the rotation, thereby forming a stitch. The controller 320 receives power from the power source 330 contained within the motor driver 110 or from an external power source via the electrical input 128 and selectively provides electrical power to the motor 310 to cause the motor 310 to provide the generated rotational force. Also as previously described, when the user engages the second control 126 (or receives a similar instruction via the electrical input 128), the controller 320 causes the motor 310 to stop or reverse as needed.

[0053] Additionally referring to Figure 4A and Figure 4B, the device 100 can be shaped to facilitate operation. In various embodiments, the shaft 130 can include an angled portion 430 to enable the housing 122 to be positioned at a first displacement 432 from the body 410 to be sutured, while the roller mechanism 150 is disposed at the location 412 where the suture is to be placed. The angled portion 430 allows the first displacement 432 to provide space for the hand ( Figure 4A ) of the human operator 404 supporting the device 100 or the actuator ( Figure 4B ) of the electromechanical device 452 to hold the device 100 in place without contacting the body 410.

[0054] Similarly, the shaft 130 can be configured to allow a second displacement 434 between the housing 120 and the roller mechanism 150 such that the housing 120 does not need to be placed adjacent to the location 412. Allowing the second displacement 434 can permit the roller mechanism 150 to be inserted into a location where the housing 120 may not fit due to other structures (not shown) or so as not to prevent the housing 120 from blocking the view of the location 412.

[0055] Referring again to Figure 4A , it should be understood that in the case where the user's hand 402 supports the device 100, the user can hold the device 110 in place with one hand and can initiate the formation of a suture by engaging the suture control 124 with the thumb 404 (or other finger, depending on the placement of the suture control 124 and the hand). Referring again to Figure 4B , in the case where the actuator 452 supports the device 100, the actuator 452 can position the device at the location 412 and can initiate the formation of a suture by sending a control signal to the electrical input 128 via the signal coupling 454. In either case, a suture can be formed at the location 412 without the need for a person to use one or both hands at the location 412 to apply the force or space required to push and pull the needle through the body to form a suture.

[0056] Referring additionally to Figure 5 , the helical needle 180 has an axis 501 about which the needle rotates when actuated by the reversely rotating rollers 156 and 158 ( Figure 1 and Figure 2 ). As shown in Figure 1 and Figure 2 , the axis 501 is not coaxially positioned with the axis of either of the rollers 156 and 158. Instead, the axis 501 is parallel to the axes of the rollers 156 and 158, whereby the needle 180 can be rotated by the rollers 156 and 158 while rotating about its own axis 501 to engage the body 410 on the side of the needle 180 opposite the side engaged between the rollers 156 and 158 ( Figure 4A and Figure 4B)。In various embodiments, the shaft 510 of the needle 180 may have a rectangular or square cross-section, as further described below. The needle 180 has a sharp leading end 512 and draws the filament 190 from the rear end 514. In various embodiments, the filament 190 is coupled to the rear end 514, such as by crimping the rear end 514 around the end of the filament 190.

[0057] Additionally refer to Figure 6 , in a cross-section of the shaft 510 of the needle 180 taken along the Figure 5 axis 6-6, the shaft 510 of the needle 180 has opposing flat surfaces 602 and 604 on opposite sides of a generally rectangular or square cross-section 600. The flat surfaces 602 and 604 have a width w s . The opposing flat surfaces 602 and 604 may be engaged on one side within the grooves 159 of the roller 158 ( Figure 1 and Figure 2 ), and on the other side may be engaged by the surface of the roller 156.

[0058] Additionally refer to Figure 7 , the shaft 510 of the needle 180 is received within the groove 159 in the roller 158. In various embodiments, the groove 159 has a rectangular cross-section. The groove 159 is defined by a generally flat bottom 712, which is defined by generally flat sides 716 that each extend to an opening 714 at the grooved surface 720 of the roller 158. The roller 156 has a flat surface 757. The shaft 510 of the needle 180 is thus engaged between the groove 159 of the roller 158 on one side and the flat surface 757 of the roller 156 on the opposite side. The rollers 156 and 158 have opening distal ends 756 and 758, respectively, at the open ends 160 of the device 100 ( Figure 1 and Figure 2 ). The opening distal ends 756 and 758 of the rollers 156 and 158 respectively allow the filament 190 to be drawn through the rear end 514 of the needle 180 ( Figure 7 not shown in

[0059] ) without the filament 190 being guided through or around a distal mount or other similar obstacle. Figure 7(not shown) are mechanically interconnected so that rollers 156 and 158 rotate in opposite directions. Alternatively, since rollers 156 and 158 are in frictional engagement with opposite sides of the shaft 510 of needle 180, rotation of either roller 156 or 158 will cause the opposite roller to rotate in the opposite direction. In various embodiments, the leading end 512 of needle 180 is arranged to advance away from the open end 160 of device 100 in direction 701 as rollers 156 and 158 rotate in opposite directions.

[0060] Continuing reference Figure 7 , it should be understood that the pitch of groove φ is proportionally matched to the pitch of needle θ according to the ratio of the helical radius R ( Figure 5 ) of needle 180 to the radius r of roller 158. Thus, when roller 158 rotates with roller 156 to actuate needle 180, needle 180 will be aligned with groove 159.

[0061] Additionally referring Figure 8 , in the case where the width W of groove 159 in roller 158 is greater than the width W s of the shaft 512 of needle 180, the shaft fits within groove 159 and the side 716 of groove 159 does not impinge on the side 810 of the shaft 512 of needle 180. Thus, the widened width W of groove 159 avoids undesirable effects such as compression of needle 180 along its axis 501. In various embodiments, a groove width W that is 20% greater than the width W s of the shaft 510 of needle 180 properly accommodates the shaft 510 of needle 180 within groove 159 without the side 716 impinging on the shaft 510 of needle 180.

[0062] Additionally referring Figure 9 , various embodiments of grooved roller 958 may include a groove 959 having two expanded sides 916 to accommodate the shaft 512 of needle 180. The purpose of groove 959 with expanded sides is to accommodate the sides of needle 180. A square or rectangular groove without tapered sides may impede needle 180 and cause needle 180 to deform as needle 180 rotates between the rollers. This tapered clearance is needed to allow the helical needle to pass between rollers 156 and 158 ( Figure 7 ) without interference from the groove. Thus, as Figure 9 shown, groove 959 expands from the bottom 912 of groove 959 to an opening 914 at the surface 920 of roller 958. Thus, groove 959 has a generally trapezoidal cross-section. When needle 180 is displaced or deformed, the width W F of groove 959 at surface 920 serves to accommodate the sides 912 of the shaft 510 of needle 180 as the shaft 510 of needle 180.

[0063] Referring Figure 10 , as the leading end 512 leaves the body being sutured (Figure 10 When not shown) and when rotating back towards the grooved roller 158, the force 1002 on the needle 180 can also cause the leading end 512 of the needle 180 to miss the groove 159. Instead of rotating into the groove 159, the leading end 512 of the needle 180 strikes the surface 1004 of the roller 158 outside the groove 159. It should be understood that the force 1002 can act in either direction, thereby potentially causing the leading end 512 of the needle 180 to miss the groove 159 on either side.

[0064] Reference Figure 11 , the calibration recess 1110 can be located at the front end 1112 of the groove 159 of the grooved roller 158. The calibration recess 1110 can be defined by the expanded lateral surfaces 1130 and 1131, which, as described below, will act as a funnel or guide to direct the leading end 512 of the needle 180 back into the groove 159. The lateral sides 1130 and 1131 define a widened area to receive the leading end 512 of the needle 180. Thus, the force 1002 does not act on the needle 180 (which would cause the leading end 512 of the needle 180 to miss the groove 159 and strike the surface 1004 of the roller 159). Instead, the leading end 512 of the needle 180 is received within the calibration recess 1110. Then, as described below, the reverse rotation of the rollers 156 and 158 will cause the calibration recess 1110 to rotate relative to the leading end 512 of the needle 180 to guide the needle 180 back into the groove 159.

[0065] Reference Figure 12 , when the rollers 156 and 158 rotate in reverse and the grooved roller 158 rotates in the direction 1220, the calibration recess 1110 rotates towards the opposite roller 156. The movement of the calibration recess 1110 causes the lateral surface 1130 of the calibration recess 1110 to strike the leading end 512 of the needle 180. The lateral surface 1130 moves the leading end 512 of the needle 180 in the direction 1240 to direct the leading end 512 towards the front end 1112 of the groove 159.

[0066] Reference Figure 13 , as the grooved roller 158 further rotates in the direction 1220, the leading end 512 of the needle is directed into the front end 1112 of the groove 159. The calibration recess ( Figure 13 not shown) will rotate into position repeatedly during subsequent rotations of the needle 180 after each stitch is formed to receive the leading end 512 of the needle 180.

[0067] Still referring to Figure 13, in various embodiments, the groove 159 may have a reduced depth d1 at or near the front end 1112 of the groove 159 compared to the regular depth d2 of the remaining portion 1350 of the groove 159. The reduced depth d1 at the front end 1112 may result in a reduced gap between the front end 1112 of the groove 159 and the opposing roller 156. Such a reduced gap may cause the opposing roller 156 to apply a higher pressure against the needle 180 at the front end 1112 of the groove 159. The reduced depth d1 (and the resulting higher pressure) enables the rollers 156 and 158 to firmly grip the needle 180 when they start their next rotation after the needle 180 has been redirected into the groove 159 through the calibration recess 1110.

[0068] Reference Figures 14 to 16 , the leading end 512 of the needle 180 is directed into the front end 1112 of the groove 159 of the grooved roller 158 by the lateral surface 1130 of the calibration recess 1110. Reference Figure 14 , the leading end 512 of the needle 180 is received in the calibration recess 1110, which is located between the lateral surfaces 1130 and 1131 that define the sides of the calibration recess 1110. As previously referenced Figure 10 stated, the leading end 512 of the needle 180 would fall outside the groove 159, the sides of which are represented by dashed lines in Figures 14 to 16 .

[0069] Reference Figure 15 , when the grooved roller 158 rotates as referenced Figure 12 and Figure 13 stated, the lateral surface 1130 of the calibration recess 1110 engages the leading end 512 of the needle 180. It should be understood that when the grooved roller 158 rotates as referenced Figure 13 stated, the calibration recess 1110 narrows between the lateral surfaces 1130 and 1131. Reference Figure 16 , when the grooved roller 158 rotates further as referenced Figure 13 stated, the lateral surfaces 1130 and 1131 of the calibration recess 1110 (not shown in Figure 16 ) merge into the front end 1112 of the groove 159. Thus, the calibration recess 1110 receives the leading end 512 of the needle 180 at a position outside the groove 159 and directs the leading end 512 of the needle 180 into the groove 159.

[0070] Reference Figure 17 and Figure 18 , the grooved roller may include calibration recesses that are different in shape from those referenced Figures 11 to 16 stated. Reference Figure 17, for example, the grooved roller 158 may include a calibration recess 1710 that is widened only on one side. For example, it is anticipated that the only force acting on the needle 180 will deflect the needle 180 in the direction 1702. Accordingly, the calibration recess 1710 may include a lateral surface 1731 that extends straight from the front end 1712 of the groove 159 and an extended lateral surface 1730 to accommodate the deflection of the leading end 512 of the needle 180 in the direction 1702. The single extended lateral surface 1730 should accommodate any anticipated deflection of the leading end 512 of the needle 180.

[0071] It should be understood that the lateral surfaces of the calibration recess are not limited to a straight extended shape. Refer to Figure 18 , for example, the calibration recess 1810 may include one or more curved or otherwise non-straight surfaces 1830 and 1831 to engage the leading end 512 of the needle 180. The curved lateral surfaces 1830 and 1831 may also be used to impact the leading end 512 of the needle 180 to guide the leading end 512 into the front end 1812 of the groove 159. The lateral surfaces of the calibration recess are not limited to any particular geometry.

[0072] Refer to Figure 19A and Figure 19B , based on the forces that may affect the movement of the helical needle 180, such as the resistance encountered by the needle 180 or the sliding of the needle 180 between the rollers 156 and 158, when the leading end 512 rotates towards the calibration recess 1110, the leading end 512 of the needle 180 may miss the calibration recess 1110.

[0073] Refer to Figure 19A , which depicts a portion of the needle 180 when the needle 180 rotates around the roller 156. It should be understood that Figure 19A and Figure 19B the axial views of the needle 180 in Figure 20A and Figure 20B show the projection of the needle 180, which describes less than a complete arc around its axis. However, in practice, the needle 180 actually describes more than a complete arc around its axis so that when the needle 180 rotates completely around its axis to form a suture, the rollers 156 and 158 can engage the shaft of the needle.

[0074] The needle 180 describes more than a complete arc around its axis to partially illustrate the narrowed and pointed leading end 512 of the needle 180, which may be too narrow to be engaged by the rollers 156 and 158. Similarly, the rear end 514 of the needle 180 (( Figure 5 ) may be narrowed or tapered to engage the material it pulls to form a suture ( Figures 19A to 20BThe filaments (not shown in [the figure]) may be too narrow to be engaged by rollers 156 and 158. Thus, the needle 180 describes more than a complete arc about its axis to allow for ends that may not be engaged by rollers 156 and 158. In any case, Figures 19A to 20B the needle 180 in [the figure] is shown as not describing a complete arc about its axis so that the position of the leading end 512 of the needle 180 can be shown and the position of the leading end 512 is not potentially obscured by an overlapping portion of the needle 180.

[0075] Continuing to refer to Figure 19A , when the needle 180 rotates in the direction 1901 due to the reverse rotation of rollers 156 and 158, the leading end 512 of the needle 180 approaches the calibration recess 1110 formed in the surface of the grooved roller 158. Referring to Figure 19B , when some of the forces described above have impeded the movement of the needle 180, the grooved roller 158 may have rotated such that the calibration recess 1110 has rotated such that the leading end 512 of the needle 180 is not received by the calibration recess 1110. Generally speaking, the radius R of the helical needle 180 will be an integer multiple of the radius r of the grooved roller such that the movement of the calibration recess 1110 is synchronized with the rotation of the needle 180 to receive the leading end 512 of the needle 180. In other words, the ratio between the radius R (or diameter) of the needle 180 and the radius r (or diameter) of the roller 158 will be an integer greater than or equal to two. However, the forces acting on the needle 180 can compromise the rotational synchronization of the needle 180 and the grooved roller 158, indicating that the radius R of the needle 180 can be less than an integer multiple of the radius r of the roller 158 (or the ratio of R to r should be less than two or another integer ratio of R to r).

[0076] Referring to Figure 20A and Figure 20B , reducing the radius of the helical needle 180 can compensate for the forces that can impede the rotation of the needle 180 to avoid synchronization problems with the grooved roller 158. Referring to Figure 20A , the radius R' of the helical needle 2090 is approximately 5% less than the radius R of the needle 180 (shown in dashed lines in Figure 20A for comparison with the needle 2090). Thus, compared to the needle 180 with a radius R that is twice the radius r of the grooved roller 158, the radius R' of the needle 2090 is approximately 1.9R or 5% less than R. With the reduced radius R', the leading end 2092 of the needle 2090 is closer to the grooved roller 158 at this point in the rotation of the needle 2090 than the leading end 512 of the needle 180. Referring to Figure 20B , when the needle 2090 rotates in the direction 2001, the leading end 2092 of the needle 2090 is received in the calibration recess 1110.

[0077] Referring to Figure 21A and Figure 21B, before the calibration recess 1110 has rotated into position to receive the leading end 2092 of the needle 2090, the leading end 2092 of the needle 2090 can reach the surface 2104 of the grooved roller 158. Since the radius R' of the needle 2090 is less than an integer multiple of the radius r of the grooved roller 158, as previously described, the needle 2090 can complete a rotation before the grooved roller 158 with a radius r (less than half of the radius of the needle 2090 in this example) completes two rotations. Therefore, it is possible that before the calibration recess 1110 is in position to receive the leading end 2092 of the needle 2090, the leading end 2092 of the needle 2090 can reach the surface 2104 of the grooved roller 158. Refer to Figure 21A , the leading end 2092 of the needle 2090 can thus strike the surface 2104 of the grooved roller 158 outside the calibration recess 1110.

[0078] However, refer to Figure 21B , when the grooved roller 158 continues to rotate in the direction 2101 opposite to the rotation of the roller 156, the calibration recess 1110 rotates under the leading end 2092 of the needle 2090. Thus, even if the leading end 2092 of the needle 2090 with radius R' should be in position to engage the calibration recess 1110 before the calibration recess 1110 is in position to receive the leading end 2092, the leading end 2092 will slide along the surface 2104 of the grooved roller 158 until it can slide into the calibration recess 1110.

[0079] Even if the leading end 2092 should reach the gap 2125 between the surface 2104 of the grooved roller 158 and the surface of the opposing roller 156 before the leading end 2092 is received into the calibration recess 1110 ( Figure 21A ), the needle 2090 cannot slide into the gap 2125 between the rollers 156 and 158. It should be recalled and understood that the size of the helical needle 180 or 2090 is set to fit between the rollers 156 and 158 only when received within the grooves 159 of the grooved roller 159. Thus, the needle 2090 is too wide to fit into the gap 2125. Therefore, the leading end 2092 of the needle 2090 will slide along the surface 2104 of the grooved roller 158 until the calibration recess 1110 rotates under the leading end 2092 of the needle 2090. At this time, the leading end 2092 of the needle 2090 will be captured by the calibration recess 1110 and guided into the groove 159, as previously referred to Figures 11 to 18 described.

[0080] In various embodiments, the roller mechanism 150 can be selectively detached from and attached to the motor drive 120. Thus, the roller mechanism 150 can be changed for hygiene reasons and / or as further described below to engage needles of different sizes. As previously described, the proximal end 152 of the frame 154 of the roller mechanism 150 engages the distal end 132 of the shaft 130. Also refer to Figure 22, in various embodiments, the roller mechanism 150 can thus be capable of disengaging the engagement between the proximal end 152 of the roller mechanism 150 and the proximal end 132 of the shaft 130. The roller mechanism 150 (including the frame 154, rollers 156 and 158, and needles 180) can be regarded as a detachable and replaceable suture bobbin 2200. Thus, the distal end 132 of the shaft 130 can include a shaft coupling 2230 configured to engage a support coupling 2210 at the proximal end 152 of the frame 150. The couplings 2230 and 2210 can include a tongue-and-groove arrangement or another structure to frictionally and / or mechanically engage the distal end 132 of the shaft 130 with the proximal end 152 of the frame 154.

[0081] Still referring to Figure 22 , in various embodiments, the shaft 130 can support one or more drive members 2260 and 2270 to transmit rotational force from the motor 310 of the motor driver 110 ( Figure 3 ). The drive members 2260 and 2270 can include rigid or semi-rigid shafts or flexible drive cables. The drive members 2260 and 2270 can be coupled to the motor 310 in different ways. In various embodiments, the drive members 2260 and 2270 can be connected to a gearbox (not shown) such that the drive members 2260 and 2270 rotate in opposite directions in response to the rotation of the motor 310 so as to rotate the rollers 156 and 158 in opposite directions, respectively. Other embodiments can include only a single drive member 2260 or 2270 to transmit rotational force from the motor 310 to one of the rollers 156 or 158. As previously described, the rollers 156 and 158 can be coupled by a gear mechanism (not shown) housed at or within the frame 154 such that one of the rollers 156 or 158 that receives the rotational force from the drive member 2260 or 2270 will cause the other roller to rotate in the opposite direction. Also as described, when one of the rollers 156 or 158 engages the drive member 2260 or 2270, the frictional engagement of the rollers 156 and 158 with the needles 180 will cause the other roller to rotate in the opposite direction. Any of these configurations can be used whether the roller mechanism 150 is fixedly attached to the motor driver 110 or if the roller mechanism 150 is part of a detachable suture bobbin 2200 from the motor driver 110.

[0082] Specifically, when the motor driver 110 is selectively detachable from and couplable to the suture spool 2200, the one or more drive members 2260 and 2270 must be detachable from and attachable to the rollers 156 and 158. In various embodiments, at least one of the rollers 156 and / or 158 respectively includes shafts 2256 and / or 2266 that extend through the frame 154 from the rollers 156 and / or 158. The shafts 2256 and / or 2268 can be respectively engaged by the drive members 2260 and / or 2270. For the purposes of the remainder of this specification, it should be understood that there can be one drive member 2260 or 2270 or two drive members 2260 and 2270 to respectively engage one shaft 2256 or 2266 or two shafts 2256 and 2266.

[0083] To facilitate the transfer of rotational force from the drive members 2260 and / or 2270 to the shafts 2256 and / or 2266, each of the shafts 2256 and / or 2266 can respectively include drive couplings 2257 and 2267. The drive couplings 2257 and 2267 include faceted ends 2259 and / or 2269. The faceted ends 2259 and / or 2269 can include shaped outer ends, such as Figure 22 the hexagonal ends shown, or can include support gear surfaces or other ends adapted to receive rotational force via the drive members 2260 and / or 2270. The drive members 2260 and / or 2270 can include faceted ends 2262 and 2272 to respectively engage the faceted ends 2259 and 2269 of the drive couplings 2266 and 2268. In various embodiments, the faceted ends 2262 and 2272 of the drive members 2260 and 2270 can respectively include inwardly facing sockets to respectively engage the outwardly facing ends of the drive couplings 2257 and 2267. Thus, when the motor driver 110 is engaged with the suture spool 2200, where the distal end 132 of the shaft 130 engages the proximal end 152 of the frame 150, the faceted ends 2262 and / or 2272 of the drive members 2260 and / or 2270 respectively engage the faceted ends 2259 and 2269 of the drive couplings 2257 and / or 2267.

[0084] As described above, when using the interchangeable suture cartridge 2200, different cartridges may have needles of different sizes for different applications. For example, a suture cartridge with a needle having a smaller helix radius may be used to form small sutures to close small wounds or incisions. Alternatively, a suture cartridge with a needle having a larger helix radius may be used to form larger sutures to close larger wounds or incisions. The suture cartridge may have rollers of different sizes. To accommodate needles of different sizes, the pitch of the grooves of the grooved roller and the pitch of the needle should be proportionally matched to ensure proper alignment of the needle with the grooves as the grooved roller rotates. Additionally, it may be advantageous to use rollers of different sizes to support needles of different sizes. For example, for suturing a small incision, a needle with a small helix radius may be desirable such that the suture closely matches the edges of the wound or incision to be closed. Accordingly, at least the roller around which the needle rotates should have a smaller radius to accommodate a needle with a smaller helix radius. Correspondingly, when a larger needle is desired to form a suture to close a larger wound or incision, a larger roller may be desirable to provide a wider surface that frictionally engages the needle as the needle rotates to form the suture.

[0085] Reference Figure 23 , two different-sized suture cartridges 2310 and 2311 respectively support different-sized needles 2380 and 2381 having different helix radii R and R'. Each of the suture cartridges 2310 and 2311 includes a support coupling 2210 configured to engage a shaft coupling 2230 of the shaft 130 such that the suture cartridges 2310 and 2311 can be mechanically supported by the shaft 130. The suture cartridges 2310 and 2311 both include a frame 154 of the same size. However, it should be understood that the frames of the suture cartridges 2310 and 2311 need not have the same size as long as these frames can equally engage the shaft 130.

[0086] Both of the suture cartridges 2310 and 2311 include a shaft 2268 having a faceted end 2269 to engage a faceted end 2272 of a drive member 2270 to provide a rotational force to the roller. Compared with Figure 1 the suture cartridge 2200, the suture cartridges 2310 and 2311 are actuated by a single drive member 2270, where gears between the rollers or frictional engagement with the needle cause the two rollers to rotate in opposite directions, as described above. The shafts 2268 and faceted ends 2269 of the suture cartridges 2310 and 2311 are both equivalent to support the interchangeability of the suture cartridges 2310 and 2311 with the drive member 2270.

[0087] The suture spool 2310 has a grooved roller 2358 with a radius of r and an opposing roller 2356, and a needle 2380 with a radius of R rotates about the opposing roller. The suture spool 2311 has a grooved roller 2359 with a radius of r' and an opposing roller 2357, and a needle 2381 with a radius of R' rotates about the opposing roller. The helical radius R' is greater than the helical radius R such that the suture spool 2311 is adapted to form a larger suture than the suture spool 2310. For both the suture spool 2310 and the suture spool 2311, the pitches of the grooves in the grooved rollers 2358 and 2359 and the helical needles 2380 and 2381 are proportionally matched. When a motor driver ( Figure 23 not shown) engages to rotate the needle 2380 or 2381, the diameters r and r' are selected such that the needles 2380 and 2381 rotate respectively to form a single suture. In various embodiments, the rollers 2356 and 2357 about which the needles 2380 or 2381 rotate respectively may have the same size or different sizes, provided that the rollers 2356 and 2357 provide a suitable frictional engagement with the needles 2380 and 2381 to drive the rotation of the needles 2380 and 2381.

[0088] Although only two sizes of suture spools 2310 and 2311 are shown, it should be understood that any number of sizes of suture spools may be present to form sutures of any size. Additionally, although Figure 22 not shown, each of the needles 2380 and 2381 will engage a filament to effect the formation of a suture.

[0089] Additionally referring to Figure 24 , a supply tray 2400 supports a plurality of interchangeable suture spools 2411 - 2418. The supply tray 2400 may include brackets 2420 to frictionally engage the sides of the suture spools to hold the suture spools 2411 - 2418 in place until they are engaged by a motor driver 110 and removed from the supply tray 2400 for use. As further described with reference to Figure 24 , in various embodiments, the supply tray 2400 supports the suture spools 2411 - 2418 using presented support couplings and drive couplings ( Figure 24 not shown) such that the motor driver 110 can engage any one of the suture spools 2411 - 2418 without the user handling or touching the supply spools 2411 - 2418. The user not having to handle or touch the supply spools 2411 - 2418 can prevent the suture spools 2411 - 2418 from being contaminated or infected by bacteria or other substances from the user's hands. To this end, the supply tray 2400 may be covered with a sanitary wrapper 2402 (shown in dashed lines) to seal the supply tray. Similarly, the motor driver 110 (which may also be held to the surface of the supply tray 2400 by a bracket 2422) can be hygienically present on the supply tray 2400.

[0090] The suture spools 2411-2418 supported by the supply tray 2400 can have different sizes to enable an operator to select an appropriate one or more suture spools for this patent application. For example, the suture spool 2410 includes a needle 2431 that is smaller than the needle 2433 of the suture spool 2413 (and thus may have a smaller roller, as previously described). Similarly, the suture spool 2417 includes a needle 2437 that is larger than the needle 2433 of the suture spool 2413. Thus, the operator can select from the available suture spools 2411-2418 to pick a suture spool that will form a suture of a size suitable for this patent application.

[0091] Additionally referring to Figure 25 , the supply tray 2400 presents the ends of the suture spools 2411-2413, where each of its support couplings 2210 and drive couplings 2266 and 2268 is presented as being accessible by the motor driver 110. As Figure 24 shown, the suture spools 2411-2413 are mechanically held to the supply tray 2400, where the carriage 2420 holds each of the suture spools 2411-2413 therebetween. Alternatively or in addition, the supply tray 2400 can include a base 2501 that forcibly engages the frame 154 of each of the suture spools 2411-2413 to hold the suture spools 2411-2413 in place. For example, the base 2501 can be an adhesive pad or a magnet that is configured to engage the frame 154 of each of the suture spools 2411-2413 to hold the suture spools 2411-2413 in position until engaged by the motor driver 110 to remove them from the supply tray 2400.

[0092] Additionally referring to Figure 26A and Figure 26B , the needle 180 forms a suture 2650 to close an opening 2601 in the body 2600, such as a wound or incision, by rotation of a roller ( Figure 26A and Figure 26B not shown). As Figure 26A shown, the needle 180 is about to rotate in the direction 2602 to pierce the body 2600 adjacent to the opening 2601. Since the needle 180 is helical, rotation of the needle 180 causes the needle 180 to be pulled in the direction 2603. The leading end 512 of the needle 180 pierces the body 2600. Rotation of the needle 180 pulls the shaft 510 of the needle 180 through the body until the trailing end 514 of the trailing filament 190 emerges from the body 400. As Figure 26B shown, after the needle 180 rotates in the direction 2602 and thus moves in the direction 2601, a loop of the filament 190 has formed a suture 2650 through the body 2600.

[0093] Additionally referring toFigure 27 , in various embodiments, an exemplary method 2700 is provided for suturing an object by rotating a helical needle, as described above. Method 2700 begins at block 2705. At block 2710, a first of two generally parallel rollers is positioned adjacent a body, where the two generally parallel rollers engage a helical needle therebetween. The needle draws a filament from a rear end and has a first helical radius greater than the radius of the first roller, and the needle is capable of rotating about the first roller such that the needle can pierce and extend through the body. At block 2720, an input is provided to a motor operably coupled to at least one of the two generally parallel rollers. The input causes the motor to rotate so as to rotate the two generally parallel rollers so as to cause the needle to complete at least one rotation, thereby forming a single suture. Method 2700 ends at block 2725.

[0094] Additionally referring Figure 28 , in various embodiments, an exemplary method 2800 is provided for forming a suture using an interchangeable suture bobbin. Method 2800 begins at block 2805. At block 2810, a suture bobbin is engaged with a motor drive, the suture bobbin supporting a pair of generally parallel rollers that rotatably engage the shaft of a helical needle therebetween. The needle is rotatable about a first roller and has a helical radius greater than the roller radius of the first roller such that the needle can pierce and extend through a body positioned adjacent the first roller. At block 2820, a first of the two generally parallel rollers is positioned adjacent the body. At block 2830, an input is provided to the motor drive, where the input causes the motor drive to rotate and the two generally parallel rollers to rotate so as to cause the needle to complete at least one rotation, thereby forming a single suture. Method 2800 ends at block 2835.

[0095] The subject matter disclosed herein includes, but is not limited to, the subject matter described in the following clauses:

[0096] 1. An apparatus, the apparatus comprising:

[0097] A roller mechanism configured to reversibly rotatably support two generally parallel rollers configured to engage the shaft of a helical needle therebetween, the needle having a tip at a leading end, drawing a filament from a rear end, and having a first helical radius, the needle being capable of rotating about a first roller, the roller radius of the first roller being less than the helical radius of the needle such that the needle can pierce a body and draw the filament through the body positioned adjacent the first roller;

[0098] A motor drive operably coupled to the roller mechanism to transmit a rotational force to rotate the two generally parallel rollers; and

[0099] A controller, the controller being operably coupled to the motor driver and configured to cause the needle to complete at least one rotation to form a single suture in the body.

[0100] 2. The device according to clause 1, wherein the motor driver supports the roller mechanism with a certain offset relative to the roller mechanism, wherein the roller mechanism can be positioned at a close distance from the body, while the handle remains positioned at a distance greater than the close distance from the body.

[0101] 3. The device according to clause 1, wherein:

[0102] The first roller includes a flat surface configured to rollingly engage a first face of the shaft of the needle; and

[0103] The second roller includes a grooved surface defining a groove configured to at least partially receive an opposite face of the shaft of the needle.

[0104] 4. The device according to clause 3, wherein the bottom of the groove has a bottom width at least as wide as the second face and is defined by side surfaces extending to the groove opening at the grooved surface, and the grooved surface has a surface width wider than the second face.

[0105] 5. The device according to clause 3, wherein the pitch of the groove is proportionally matched to the pitch of the needle according to the ratio of the radius of the needle to the radius of the second roller.

[0106] 6. The device according to clause 3, wherein the second roller further defines a correction recess defined by a lateral surface at the front end of the groove, the correction recess tapering to the width of the groove at the front end of the groove, and wherein when the leading end is received in the correction recess in response to reverse rotation of the first roller and the second roller, at least one of the lateral surfaces engages the leading end and guides the leading end into the front end of the groove.

[0107] 7. The device according to clause 1, wherein the roller mechanism includes an open distal end, wherein the ends of the two substantially parallel rollers are exposed, and wherein the rear

[0108] end of the needle faces the open distal end to draw the filament from the open distal end.

[0109] 8. The device according to clause 1, wherein the roller mechanism is configured to receive the rotational force from the motor driver and apply the rotational force to at least one of the first roller and the second roller.

[0110] 9. The device according to clause 1, wherein the controller is configured to receive an instantaneous input, the instantaneous input being configured to cause the needle to complete at least one rotation to form a single suture in the body.

[0111] 10. The device according to clause 1, wherein the controller is configured to receive a reverse input, the reverse input being configured to cause the motor driver to rotate the needle in a reverse direction.

[0112] 11. A system, the system comprising:

[0113] A helical needle having a helical radius, the needle having a tip at a first end of the shaft and a filament joined to the second end;

[0114] A roller mechanism configured to rotatably support two substantially parallel rollers, the two substantially parallel rollers being configured to engage the shaft of the needle therebetween, the needle being capable of rotating about a first roller, the roller radius of the first roller being less than the helical radius of the needle, such that the first end of the needle can pierce the body and pull the filament through the body disposed adjacent to the first roller; and

[0115] A motor driver, the motor driver comprising:

[0116] A motor operably coupled to the roller mechanism to transmit a rotational force to cause the two substantially parallel rollers to rotate;

[0117] A controller operably coupled to the motor and configured to cause the needle to complete at least one rotation to form a single suture in the body; and

[0118] An interaction device configured to enable the motor driver to be supported by one of a human user and a robotic actuator.

[0119] 12. The system according to clause 11, wherein the motor driver supports the roller mechanism with a certain offset relative to the roller mechanism, wherein the roller mechanism can be positioned at a short distance from the body, while the handle remains positioned at a distance greater than the short distance from the body.

[0120] 13. The system according to clause 11, wherein:

[0121] The first roller includes a flat surface configured to rollably engage a first face of the shaft of the needle; and

[0122] The second roller includes a grooved surface defining a groove configured to at least partially receive a relative second face of the shaft of the needle.

[0123] 14. The system according to clause 13, wherein the bottom of the groove has a bottom width that is at least as wide as the second face and is defined by the sides of the groove opening extending to the grooved surface, and the grooved surface has a surface width wider than the second face.

[0124] 15. The system according to clause 13, wherein the pitch of the groove is proportionally matched to the pitch of the needle according to the ratio of the radius of the needle to the radius of the second roller.

[0125] 16. The apparatus according to clause 13, wherein the second roller further defines a calibration recess, the calibration recess being defined by the lateral surfaces at the front end of the groove, the calibration recess tapering to the width of the groove at the front end of the groove, and wherein when the leading end is received in the calibration recess in response to the reverse rotation of the first roller and the second roller, at least one of the lateral surfaces engages the leading end and guides the leading end into the front end of the groove.

[0126] 17. The system according to clause 11, wherein the roller mechanism includes an opening distal end, wherein the ends of the two substantially parallel rollers are exposed, and wherein the rear end of the needle faces the opening distal end to draw the filament from the opening distal end.

[0127] end faces the opening distal end to draw the filament from the opening distal end.

[0128] 18. The system according to clause 11, wherein the controller is configured to receive an instantaneous input, the instantaneous input being configured to cause the needle to complete at least one rotation to form a single suture in the body.

[0129] 19. The system according to clause 11, wherein the controller is configured to receive a reverse input, the reverse input being configured to cause the motor driver to rotate the needle in a reverse direction.

[0130] 20. A method, the method comprising:

[0131] Positioning a first roller of two substantially parallel rollers adjacent to a body, wherein the two substantially parallel rollers engage a helical needle therebetween, the needle drawing a filament from a rear end and having a first helical radius greater than the radius of the first roller, wherein the needle is capable of rotating about the first roller such that the needle is capable of piercing and extending through the body; and

[0132] and

[0133] An input is provided to a motor, the motor being operably coupled to at least one of the two generally parallel rollers, wherein the input causes the motor to rotate so as to rotate the two generally parallel rollers so as to cause the needle to complete at least one rotation, thereby forming a single suture.

[0134] 21. An apparatus, the apparatus comprising:

[0135] A helical needle having a first helical radius, the needle having a shaft and pulling a filament from a rear end;

[0136] Two generally parallel rollers configured to engage the shaft of the needle therebetween, the first roller having a roller radius less than the helical radius of the needle so that the needle can rotate about the first roller to pierce a body disposed adjacent to the first roller and pull the filament through the body; and

[0137] A frame configured to rotatably support the rollers reversibly and comprising:

[0139] A support coupling configured to removably receive a distal end of a support shaft extending from a drive mechanism; and

[0140] A drive coupling configured to removably receive a distal end of a drive member extending from the drive mechanism, the drive member being configured to provide the rotational force to at least one of the rollers.

[0141] 22. The apparatus according to clause 21, further comprising at least one drive member configured to removably engage the drive mechanism.

[0142] 23. The apparatus according to clause 21, wherein the drive member includes a shaft extending from an end of one of the rollers and having a faceted end configured to removably engage the drive mechanism.

[0143] 24. The apparatus according to clause 21, wherein the frame can be engaged by a supply tray, wherein

[0144] the supply tray is configured to apply a force to the frame to hold the frame in place unless the support shaft engages the frame and separates the frame from the supply tray.

[0145] 25. The apparatus according to clause 21, wherein:

[0146] the first roller includes a flat surface configured to rollably engage a first side of the shaft of the needle; and

[0147] The second roller includes a grooved surface defining grooves configured to at least partially receive the second side of the shaft of the needle.

[0148] 26. The apparatus according to clause 25, wherein the pitch of the grooves is proportionally matched to the pitch of the needles according to the ratio of the radius of the needles to the radius of the second roller.

[0149] 27. The apparatus according to clause 21, wherein the frame includes an open distal end at an end opposite to the support coupling, and wherein the needles are received between the rollers, and wherein the tail end of the needles faces the open distal end to draw the filament from the open distal end.

[0150] 28. A system, the system comprising:

[0151] A drive mechanism, the drive mechanism comprising:

[0152] A housing;

[0153] A motor supported by the housing;

[0154] A support shaft extending from the housing; and

[0155] A drive member coupled to the motor and supported by the shaft, the drive member being configured to transmit rotational force from the motor; and

[0156] A suture bobbin, the suture bobbin comprising:

[0157] A helical needle having a first helical radius, the needle having a shaft and drawing a filament from a rear end;

[0158] Two generally parallel rollers configured to engage the shaft of the needle therebetween, the first roller having a roller radius smaller than the helical radius of the needle to enable the needle to rotate about the first roller to pierce a body disposed adjacent to the first roller and draw the filament through the body; and

[0159] A frame configured to rotatably support the rollers reversibly and comprising:

[0160] A support coupling configured to removably receive a distal end of the support shaft; and a drive coupling configured to removably receive a distal end of the drive member and transmit the rotational force to at least one of the rollers.

[0161] 29. The system according to clause 28 further includes a controller, wherein in response to a user input, the stitching controller causes the motor to rotate through a plurality of turns to cause the needle to complete at least one rotation to form a single stitch.

[0162] 30. The system according to clause 28 further includes a plurality of switchable spools, the plurality of switchable spools being configured to interchangeably receive the shaft of the handle and the drive coupler.

[0163] 31. The system according to clause 30, wherein the plurality of switchable spools include spools of different sizes, wherein each spool of the different sizes supports a needle having a different spiral radius, and wherein each of the plurality of switchable spools is configured to form stitches of different sizes.

[0164] 32. The system according to clause 31, wherein the first roller of the different sized spools has a different roller radius.

[0165] 33. The system according to clause 31, wherein the drive coupler of each of the spools is configured to cause the needle to complete the at least one rotation to form the single stitch, regardless of the size of the spiral radius of the needle.

[0166] 34. The system according to clause 33, wherein the drive coupler includes at least one faceted member, the at least one faceted member being coupled to one of the rollers to receive the faceted end of the drive member.

[0167] 35. The system according to clause 28, wherein:

[0168] the first roller includes a flat surface configured to rollingly engage a first side of the shaft of the needle; and

[0169] the second roller includes a grooved surface defining a groove configured to at least partially receive a second side of the shaft of the needle.

[0170] 36. The system according to clause 28, wherein the pitch of the groove is proportionally matched to the pitch of the needle according to the ratio of the radius of the needle to the radius of the second roller.

[0171] 37. The system according to clause 28, wherein the spool includes an open distal end, wherein the ends of the two generally parallel rollers are exposed, and wherein the rear end of the needle faces the open distal end to draw the filament from the open distal end.

[0172] 38. A method, the method comprising:

[0173] Engage a suture bobbin with a motor drive, the suture bobbin supporting a pair of generally parallel rollers, the pair of generally parallel rollers rotatably engaging the shaft of a helical needle therebetween, the needle being rotatable about a first roller and having a helical radius greater than the roller radius of the first roller such that the needle is capable of piercing and extending through a body disposed adjacent the first roller;

[0174] Position the first of the two generally parallel rollers adjacent the body; and

[0175] Provide an input to the motor drive, the input causing the motor drive to rotate and the two generally parallel rollers to rotate such that the needle completes at least one rotation to form a single suture.

[0176] 39. The method according to clause 38, further comprising selecting the suture bobbin from one of a plurality of suture bobbins of different sizes, each of the plurality of suture bobbins supporting a needle having a different helical radius, each of the plurality of switchable suture bobbins being configured to form sutures of different sizes.

[0177] 40. The method according to clause 39, further comprising coupling the motor drive to the selected suture bobbin.

[0178] It should be understood that the detailed description set forth above is exemplary in nature only and that variations that do not depart from the gist and / or spirit of the subject matter protected by the claims are intended to be within the scope of the claims. Such variations should not be regarded as departing from the spirit and scope of the subject matter protected by the claims.

Claims

1. A system, comprising: A helical needle having a radius, the needle having a tip at a first end of the shaft and a filament joined to the second end; A roller mechanism including a frame supporting a first roller and a second roller disposed substantially parallel, the first roller and the second roller being configured to engage the shaft of the needle therebetween, the needle being capable of rotating about the first roller, wherein the roller radius of the first roller is less than the radius of the helical needle such that the first end of the needle can pierce a body and draw the filament through the body disposed adjacent to the first roller, and the second roller has a surface defining a groove therein, the groove being configured to at least partially receive the shaft of the needle; And A motor driver, comprising: A motor that can be operatively coupled to the roller mechanism to transmit a rotational force to rotate the first roller and the second roller such that the first roller and the second roller rotate in opposite directions; And An interaction device configured to enable the motor driver to be supported by one of a human user and a robotic actuator.

2. The system according to claim 1, wherein the motor driver supports the roller mechanism with a certain offset relative to the motor driver, wherein the roller mechanism can be positioned at a close distance from the body while the handle remains positioned at a distance greater than the close distance from the body.

3. The system according to claim 1, wherein the bottom of the groove has a bottom width at least as wide as the shaft of the needle and is bounded by sides extending to the groove opening, the surface width of the groove opening being wider than the opposite faces of the shaft of the needle.

4. The system according to claim 1, wherein the pitch of the groove is proportionally matched to the pitch of the needle according to the ratio of the radius of the needle to the radius of the second roller.

5. The system according to claim 1, wherein the second roller further defines a correction recess bounded by a lateral surface at the front end of the groove, the correction recess tapering to the width of the groove at the front end of the groove, and wherein when a leading end is received in the correction recess in response to the reverse rotation of the first roller and the second roller, at least one of the lateral surfaces engages the leading end and guides the leading end into the front end of the groove.

6. The system according to claim 1, wherein the roller mechanism includes an open distal end, wherein the ends of the first roller and the second roller are exposed, and the rear end of the needle faces the open distal end to draw the filament from the open distal end.

7. The system according to claim 1, wherein the motor driver is configured to receive an instantaneous input configured to cause the needle to complete at least one rotation to form a single suture in the body.

8. The system according to claim 1, wherein the motor driver is configured to receive a reverse input configured to cause the motor driver to rotate the needle in a reverse direction.

9. The system according to claim 1, wherein the first roller is a grooveless roller.

10. The system according to claim 1, wherein the frame is removably couplable to a shaft extending from a handle of the interaction device.

11. The system according to claim 1, wherein the frame includes a gear mechanism that is couplable to the motor to rotate the first roller in a direction opposite to the second roller.

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