Reusable surgical port with disposable seal assembly

Abstract

The present invention relates to reusable surgical ports with a disposable seal assembly. A surgical port includes a housing and a seal assembly. The housing has an outer shell and a sleeve extending from the outer shell. The outer shell has a sidewall defining a window through the sidewall. The seal assembly includes one or more seals. The seal assembly is selectively receivable into the outer shell through the window of the outer shell of the housing.

Description

TECHNICAL FIELD

[0001] The present disclosure relates generally to surgical instruments, and in particular to surgical ports with reusable and / or disposable components for use in minimally invasive surgical procedures, such as robotic surgical procedures. BACKGROUND

[0002] Robotic surgical systems have been used in minimally invasive medical procedures. Some robotic surgical systems include robotic arms having instrument drive assemblies, such as a pair of jaw members, electrosurgical forceps, a cutting instrument, or any other endoscopic or open surgical device, coupled thereto to couple a surgical instrument to the robotic arm, and mounting assemblies, such as a trocar or a surgical port, an optical device, etc., coupled thereto to couple a surgical accessory to the robotic arm.

[0003] Prior to or during use of the robotic system, a surgical instrument is selected and connected to the instrument drive assembly of each robotic arm, where the instrument drive assembly can drive actuation of an end effector of the surgical instrument. In certain surgical procedures, a surgical accessory, such as an optical device or a surgical port, can be coupled to the robotic arm through the mounting assembly of the robotic arm. During the surgical procedure, an end effector and / or a portion of the surgical instrument can be inserted through the surgical port and a small incision or natural orifice of the patient to bring the end effector in proximity to a work site within the patient's body. Such surgical ports can provide additional stability for the surgical instrument during insertion and actuation of the end effector and act as a guide channel.

[0004] Given the loads and moments that can be applied during a robotic surgical procedure, high strength surgical ports are needed to provide additional functionality. Surgical ports made of plastic materials can not be durable enough for high moments applied by the surgical robotic arms, but metal components are expensive. SUMMARY

[0005] The present disclosure relates to a surgical port system having a housing and a disposable sealing assembly that is selectively receivable into and / or removable from the housing. The housing can be 3D printed. In embodiments, the housing can comprise titanium. The housing can be configured to be lightweight yet able to withstand high loads. The disposable sealing assembly, which can be in the shape of a hockey puck, can comprise plastic and / or rubber materials designed to seal against the housing and be able to pass internally by laparoscopic instruments that are advanced through the sealing assembly and the housing. The housing can define a window through which the sealing assembly passes. The sealing assembly is configured to rotate within and relative to the housing for camming along the housing for snap fit onto the housing. With the sealing assembly secured to the housing by snap fit, the sealing assembly is sealed against the housing and against instruments that pass internally therethrough. The sealing assembly can be removed from the housing and discarded, for example, after a surgical procedure. With the sealing assembly removed, the housing can be sterilized for reprocessing and reuse with another sealing assembly.

[0006] According to one aspect, the present disclosure relates to a surgical port comprising a housing and a sealing assembly. The housing has an outer shell and a sleeve extending from the outer shell. The outer shell has a sidewall defining a window through the sidewall. The sealing assembly comprises one or more seals. The sealing assembly is selectively receivable into the outer shell through the window of the outer shell of the housing.

[0007] In embodiments, the sealing assembly is selectively rotatable relative to the housing to secure the sealing assembly onto the housing. The sealing assembly is selectively removable from the housing.

[0008] In various embodiments, the housing can comprise a reusable material and the sealing assembly can comprise a disposable material. The housing can comprise titanium and the sealing assembly can comprise plastic and / or rubber.

[0009] In many embodiments, the sealing assembly can comprise a floating seal and a duckbill seal.

[0010] In embodiments, the sealing assembly can comprise a detent and the housing can define a detent slot positioned to receive the detent for securing the sealing assembly to the housing.

[0011] In various embodiments, the sealing assembly can support a gasket to seal the sealing assembly within the housing.

[0012] In some embodiments, the sealing assembly can comprise a sealing outer shell having a first geometry. The window can have a second geometry. The first geometry can key to the second geometry. The sealing outer shell can comprise a tooth and the window can comprise a tooth slot positioned to receive the tooth when the sealing outer shell is slid laterally into the window.

[0013] According to another aspect, the present disclosure relates to a surgical port system. The surgical port system includes a first sealing assembly including one or more seals, a second sealing assembly including one or more seals, and a housing. The housing has an outer shell and a sleeve extending from the outer shell. The outer shell has a sidewall defining a window through the sidewall, the window configured to receive the first and second sealing assemblies therethrough such that the housing can support one of the first or second sealing assemblies therein at any given time.

[0014] In embodiments, each of the first and second sealing assemblies is selectively rotatable relative to the housing to secure the respective first or second sealing assembly to the housing. The respective first or second sealing assembly is selectively removable from the housing.

[0015] In various embodiments, the housing can include a reusable material, and each of the first and second sealing assemblies can include a disposable material. The housing can include titanium, and each of the first and second sealing assemblies can include at least one of a plastic or a rubber.

[0016] In some embodiments, at least one of the first or second sealing assemblies can include a floating seal and a duckbill seal.

[0017] In many embodiments, each of the first and second sealing assemblies can include a detent, and the housing can define a detent slot positioned to receive the detent for securing one of the first or second sealing assemblies to the housing.

[0018] In embodiments, each of the first and second sealing assemblies can support a gasket to seal one of the first or second sealing assemblies within the housing.

[0019] In some embodiments, each of the first and second sealing assemblies can include a tooth, and the window of the housing can include a tooth slot positioned to receive the tooth of the first and second sealing assemblies.

[0020] According to yet another aspect, the present disclosure relates to a method for sealing a surgical instrument through a surgical port system. The method includes inserting a first disposable sealing assembly through a window defined in a sidewall of an outer shell of a housing, the housing including a sleeve extending from the outer shell. The method further includes rotating the first disposable sealing assembly relative to the outer shell to secure the first disposable sealing assembly to the housing to provide a surgical port assembly that enables a surgical instrument to remain sealed as such surgical instrument is advanced through the surgical port assembly. The method also includes selectively removing the first disposable sealing assembly from the outer shell to selectively replace with a second disposable sealing assembly receivable through the window of the outer shell.

[0021] The details of one or more aspects of the disclosure are set forth in the accompanying drawings and the description below. Other aspects, features, and advantages will become apparent from the description, the drawings, and the claims. BRIEF DESCRIPTION OF DRAWINGS

[0022] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and together with the description, explain the principles of the disclosure.

[0023] Figure 1 is a perspective view of a surgical port system;

[0024] Figure 2 is Figure 1 is a perspective view of a surgical port system;

[0025] Figure 3 is Figure 1 and Figure 2 is a perspective view of a seal assembly of a surgical port system;

[0026] Figure 4 is Figure 1 and Figure 2 is a perspective view of a housing of a surgical port system;

[0027] Figure 5 is an enlarged cross-sectional view of the housing of Figure 2 taken along section line 5-5 shown in Figure 4 ;

[0028] Figure 6 is an enlarged cross-sectional view of a seal assembly of Figure 2 and Figure 1 taken along section line 6-6 shown in Figure 2 ;

[0029] Figure 7 is an enlarged cross-sectional view of the housing of Figure 5 taken along section line 7-7 shown in Figure 4 ;

[0030] Figure 8 is an enlarged cross-sectional view of a seal assembly of Figure 2 taken along section line 8-8 shown in Figure 3 ;

[0031] Figures 9-13 is a progression view showing a seal assembly of Figure 3 being secured to the housing of Figure 4 ; and

[0032] Figure 14 is taken alongFigure 12 the cross-sectional view taken along section line 14-14 shown Figure 1 and Figure 2 an enlarged cross-sectional view of a distal end portion of the surgical port system. DETAILED DESCRIPTION

[0033] Aspects of the disclosure are described in detail with reference to the attached drawing figures, wherein the same elements are referred to by the same reference numerals throughout the several views. Also, the terminology used herein is for the purpose of describing particular aspects only and is not intended to be limiting - as one of ordinary skill in the art will appreciate, the terminology can be interchangeable where appropriate. Furthermore, the terms "proximal" or "distal" refer to the portion of the structure closer to or further from the clinician, respectively, and the terms "distal" or "proximal" refer to the portion of the structure closer to or further from the clinician, respectively. As is well understood by those skilled in the art, the term "clinician" refers to a physician (e.g., surgeon), nurse, or any other care provider, and can include support personnel.

[0034] In the following description, well-known functions or constructions are not described in detail because they would obscure the disclosure in unnecessary detail.

[0035] With reference to Figure 1 , the surgical port system 100 is a multi-piece construction including a housing 200, which can be autoclavable and reusable, and a seal assembly 300, which is selectively removable from the housing 200 and disposable when removed from the housing 200. The housing 200 can include any suitable material, such as a metallic material, such as titanium. The seal assembly 300 can include any suitable material, such as a plastic and / or rubber.

[0036] With reference to Figures 2-8The housing 200 of the surgical port system 100 includes a shell 210 supported on a trailing end portion of the housing 200, and an elongated cannula 220 extending distally from the shell 210 to an insertion tip 222 on a leading end portion of the cannula 220. The housing 200 defines a longitudinal axis "L" and a central passageway 230 extending along the longitudinal axis "L" from a proximal end portion of the shell 210 distally through a distal end portion of the insertion tip 222 of the cannula 220 to receive a surgical instrument (not shown) therethrough. Such surgical instruments can include graspers, forceps, staplers, endoscopes, clip appliers, suturing devices, etc. The shell 210 defines a window 212 through a sidewall 210x of the shell 210 keyed to the seal assembly 300 to receive the seal assembly 300 within an internal cavity 214 defined by the shell 210. The window 212 is defined by an angled bottom edge 212a having a tooth gap 212b, a first side edge 212c extending from a first side of the angled bottom edge 212a, a second side edge 212d extending from the tooth gap 212b on a second side of the angled bottom edge 212a, and a top edge 212e connecting the first side edge 212c and the second side edge 212d. The shell 210 further defines a detent slot 216 angularly offset from the window 212 of the shell 210 to couple the seal assembly 300 to the housing 200. The shell 210 also includes a keying track 218 along which the seal assembly 200 is configured to cam to the detent slot 216 of the shell 210.

[0037] The seal assembly 300 of the surgical port system 100 includes a seal housing 310 and a gasket 320 (e.g., an O-ring) supported by the housing 310. The seal housing 310 defines an opening 312 extending longitudinally through the seal housing 310 and a gasket channel 314 extending around an upper surface of the seal housing 310 to selectively receive the gasket 320 therein. The seal housing 310 can include an upper housing 310a and a lower housing 310b that can be integrally (e.g., monolithically) formed together as a unit or separate portions of the seal housing 310 that can be selectively secured together using any suitable securing technique, such as fastening, welding, gluing, snap-fitting, friction-fitting, etc., or combinations thereof. The seal housing 310 has a geometry that keys to the window 212 of the housing 210 of the housing 200 and is configured to be received within the interior cavity 214 of the housing 210 of the housing 200 through the window 212 of the housing 210 of the housing 200. The seal housing 310 of the seal assembly 300 includes an angled bottom edge 310c that corresponds to the angled bottom edge 212a of the housing 210 of the housing 200. The seal housing 310 further includes a pawl 316 that extends radially outward from an outer lateral surface of the seal housing 310 and is configured to move and flex away from the outer lateral surface of the seal housing 310 to selectively engage the pawl slot 216 of the housing 210 of the housing 200. In some embodiments, the pawl 316 can be formed from any suitable flexible material. The seal housing 310 further includes a tooth 318 that depends distally from the seal housing 310.

[0038] As seen in Figure 3 The seal housing 310 of the seal assembly 300 supports a floating seal 322 and a duckbill seal 326 separated by a disc 324. In embodiments, the disc 324 can be integral with the seal housing 310. In some embodiments, the floating seal 322 can be positioned on the duckbill seal 326. The floating seal 322 includes a septum seal 322a and a plurality of resilient fingers 322b that extend radially outward from the floating seal 322 at locations spaced around the floating seal 322 to enable the floating seal 322 to float within the seal housing 310.

[0039] Referring to Figures 9-14 As indicated by arrow “A,” the seal assembly 300 can be inserted into (e.g., slid laterally into) the housing 210 of the housing 200 when features of the seal assembly 300 are aligned with the window 212 of the housing 200. For example, the seal assembly 300 can be received into the interior cavity 214 of the housing 200 through the window 212 when the tooth 318 of the seal housing 310 is aligned with the tooth slot 212b of the housing 200 such that the seal assembly 300 and the central longitudinal axis of the housing 200 are aligned with one another, as indicated by arrow “B.”Figure 11 As seen, with the seal assembly 300 seated within the internal cavity 214, the seal assembly 300 can be rotated (e.g., manually by a clinician) about the longitudinal axis“L” such that as the pawl 316 of the seal assembly 300 cams along the angled bottom edge 212a of the housing 200 defining the window 212 of the housing 200, the teeth 318 of the seal assembly 300 cam along the keyed track 218 of the housing 200, as indicated by arrow“B”. Such camming movement of the seal assembly 300 relative to the housing 200 moves the seal assembly 300 to rotate upwardly along the longitudinal axis such that the pawl 316 of the seal assembly 300 can snap fit into the pawl slot 216 of the housing 200 to rotationally and longitudinally secure the seal assembly 300 to the housing 200 to seal (e.g., seal and lock) surgical instruments passing through the surgical port assembly 300. With the seal assembly 300 secured to the housing 200, the surgical port assembly 300 can be used to provide access to a body cavity, e.g., a patient’s abdominal cavity, etc. With this configuration of the surgical port assembly 300, torque applied to the surgical port assembly 300, e.g., by a robotic system (not shown) attached thereto, is received through the housing 200 while bypassing the seal assembly 300, thereby reducing the risk of failure.

[0040] The seal assembly 300 can be removed from the housing 200, e.g., after use of the surgical port assembly 300, by actuating (e.g., pressing) the pawl 316, passing through the pawl slot 216 into the internal cavity 214 of the housing 200, and rotating the seal assembly 300 until the teeth 318 of the seal assembly 300 are re-aligned with the tooth gap 212b of the housing 200. Once the teeth 318 of the seal assembly 300 are aligned with the tooth gap 212b of the housing 200, the seal assembly 300 can be removed and discarded from the housing 200. Subsequently, the housing 200 can be sterilized as needed and a new seal assembly 300 can be inserted into the housing 200, as detailed above, for subsequent use.

[0041] It can be appreciated that any of the disclosed components of the surgical port assembly 100 can be made from additive manufacturing, e.g., 3D printing.

[0042] The various surgical ports disclosed herein can also be configured for use with robotic surgical systems, and which are commonly referred to as "tele-surgery." Such systems use various robotic elements to assist the clinician, and allow for remote operation (or partial remote operation) of surgical instruments. Various robotic arms, gears, cams, pulleys, electric and mechanical motors, etc. can be employed for this purpose, and robotic surgical systems can be designed to assist the clinician during a surgical or therapeutic procedure. Such robotic systems can include remotely manipulatable systems, automated flexible surgical systems, remote flexible surgical systems, remote articulated surgical systems, wireless surgical systems, modular or selectively configurable teleoperated surgical systems, etc.

[0043] Robotic surgical systems can be employed with one or more control consoles proximate the surgical theater or positioned at a remote location. In this case, one team of clinicians can prepare the patient for surgery and configure the robotic surgical system with one or more instruments disclosed herein, while another clinician (or team of clinicians) remotely controls the instruments through the robotic surgical system. It will be appreciated that a highly skilled clinician can perform multiple operations in multiple locations without leaving his / her remote control console, which is economically advantageous and beneficial to the patient or series of patients. For detailed descriptions of exemplary medical workstations and / or components thereof, reference can be made to U.S. Patent No. 8,828,023 and PCT Application Publication No. WO 2016 / 025132, the entireties of each of which are incorporated herein by reference.

[0044] For more detailed descriptions of similar surgical ports, one or more components of which can be included in the disclosed embodiments, reference can be made to U.S. Patent No. 5,807,338, filed October 20, 1995, and U.S. Patent No. 5,603,702, filed August 8, 1994, the entireties of each of which are incorporated herein by reference.

[0045] Those skilled in the art will appreciate that the structure and methodology specifically described herein and shown in the drawings are non-limiting example embodiments, and that the description, disclosure and drawings should be interpreted only as examples of the specific embodiments. It will therefore be understood that the present disclosure is not limited to the precise embodiments described, and that various other changes or modifications can be effected by one skilled in the art without departing from the scope or spirit of the present disclosure. Moreover, it is contemplated that elements and features shown or described in connection with one example embodiment can be combined with elements and features of another example embodiment, without departing from the scope of the present disclosure, and that such modifications and variations are also intended to be included within the scope of the present disclosure. Indeed, any combination of any disclosed elements and features is within the scope of the present disclosure. Accordingly, the subject matter of the present disclosure is not to be limited by what has been particularly shown and described.

Claims

1. A surgical port comprising: A housing having a housing shell and a sleeve extending from the housing shell, the housing defining a longitudinal axis extending from a proximal portion of the housing shell to a distal portion of the sleeve, the housing shell having an inner cavity and sidewalls, the sidewalls defining windows through the sidewalls; as well as A first sealing assembly and a second sealing assembly, each of the first sealing assembly and the second sealing assembly comprising a sealing housing and at least one seal, wherein the window of the housing housing is configured to receive the first sealing assembly and the second sealing assembly passing through it, such that the interior cavity of the housing is capable of supporting one of the first sealing assembly or the second sealing assembly at any given time; The housing has a bonding track and a pawl groove offset at an angle to the window of the housing. Each sealing housing has a geometry that bonds to the geometry of the window of the housing, the window also including a toothed slot. Each sealing assembly has a pawl and at least one tooth, whereby the alignment of the tooth of the sealing assembly with the toothed slot allows the sealing assembly to be received laterally through the window and placed within the cavity of the housing. The sealing assembly is rotatable about the longitudinal axis, causing the tooth to cam along the bonding track of the housing, so that the pawl of the sealing assembly is received within the pawl groove of the housing to rotatably and longitudinally fix the sealing assembly to the housing.

2. The surgical port of claim 1, wherein the housing comprises a reusable material and the sealing assembly comprises a disposable material.

3. The surgical port of claim 2, wherein the housing comprises titanium and the sealing assembly comprises at least one of plastic or rubber.

4. The surgical port of claim 1, wherein the sealing assembly comprises a floating seal and a duckbill seal.

5. The surgical port of claim 1, wherein the sealing assembly supports the gasket to seal the sealing assembly within the housing.

6. A method for sealing surgical instruments via a surgical port system before or after a surgical procedure, the method comprising: Prior to the surgical procedure, a first disposable sealing assembly including teeth is aligned with a window defined in the sidewall of the housing, the window having a geometry that is bonded to the geometry of the sealing assembly, the window including a gap for receiving the teeth, and the housing including a sleeve extending from the housing. The first disposable sealing assembly is inserted laterally through the window to place the sealing assembly inside the cavity of the housing; The first disposable sealing assembly is rotated relative to the housing so that the teeth of the sealing assembly make a cam movement along the bonding track of the housing, so that the pawl of the sealing assembly is housed in the pawl groove of the housing, thereby rotatably and longitudinally fixing the first disposable sealing assembly to the housing. as well as After the procedure, the first disposable sealing assembly is selectively removed from the housing and selectively replaced with a second disposable sealing assembly that can be received through the window of the housing.

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