Drive mechanisms and articulation mechanisms of surgical instruments used in robotic surgical systems

Abstract

A gearbox assembly for a surgical instrument includes an articulation subassembly and a jaw drive subassembly. The articulation subassembly is configured to articulate an end effector of the surgical instrument, and the jaw drive subassembly is configured to move the jaw members of the end effector between an open position and a closed position. The articulation subassembly includes two input shafts, a proximal plate, an intermediate plate, two central gears, and four lead screws with four nuts. The jaw drive subassembly includes a drive rod coupled to at least one of the jaws and a spring force assembly for maintaining force between the jaws.

Description

Technical Field

[0001] The present disclosure relates to surgical instruments, and more particularly to drive mechanisms and articulation mechanisms for surgical instruments used, for example, in robotic surgical systems. Background Art

[0002] Robotic surgical systems are increasingly used in a variety of surgical procedures. Some robotic surgical systems include a console that supports a robotic arm. One or more different surgical instruments can be configured for use with the robotic surgical system and can be selectively mounted to the robotic arm. The robotic arm provides one or more inputs to the mounted surgical instruments to enable their operation.

[0003] The number, type, and configuration of inputs provided by the robotic arm of a robotic surgical system impose constraints on the design of surgical instruments configured for use with the robotic surgical system. That is, when designing a surgical instrument suitable for mounting on and use with the robotic arm of a robotic surgical system, consideration should be given to determining how to utilize the available inputs provided by the robotic arm to achieve the desired functionality of the surgical instrument. Summary of the Invention

[0004] As used herein, the term "distal" refers to the portion being described that is farther from the surgeon, while the term "proximal" refers to the portion being described that is closer to the surgeon. Terms such as "about," "substantially," and the like as used herein are intended to account for manufacturing, material, environmental, usage, and / or measurement tolerances and variations. Furthermore, any aspect described herein may be used in combination with any or all other aspects described herein, to the extent consistent.

[0005] According to various aspects of the present disclosure, a surgical instrument is provided, comprising: a housing; a shaft extending from the housing; an end effector coupled to a distal portion of the shaft; and a gearbox assembly disposed within the housing. The gearbox assembly includes an articulation subassembly configured to articulate the end effector about a longitudinal axis defined by the shaft. The articulation subassembly includes: a first lead screw comprising a gear portion, a waist portion, and an elongated threaded body portion; and a second lead screw comprising a gear portion and an elongated threaded body portion. A first nut is threadedly engaged with the elongated threaded body portion of the first lead screw such that rotation of the first lead screw causes longitudinal translation of the first nut. A second nut is threadedly engaged with the elongated threaded body portion of the second lead screw such that rotation of the second lead screw causes longitudinal translation of the second nut. The articulation subassembly also includes an intermediate plate comprising an intermediate plate rod extending proximally therefrom, and a proximal central gear and a distal central gear coupled to the intermediate plate rod. Each of the proximal central gear and the distal central gear includes a proximal gear portion and a distal gear portion. The distal gear portion of the proximal central gear meshes with the gear portion of the first lead screw. Furthermore, the distal gear portion of the distal central gear meshes with the gear portion of the second lead screw, and the proximal gear portion of the distal central gear is aligned with the waist portion of the first lead screw.

[0006] In one aspect, the articulation subassembly includes a first input shaft and a second input shaft. The first input shaft includes a gear portion that meshes with a proximal gear portion of the proximal sun gear, such that rotation of the first input shaft causes rotation of the proximal sun gear and the first lead screw. The second input shaft includes a first input shaft that includes a gear portion that meshes with the proximal gear portion of the proximal sun gear, such that rotation of the first input shaft causes rotation of the proximal sun gear and the first lead screw.

[0007] In one aspect, the articulation subassembly includes a proximal plate aligning the first input shaft with the first lead screw.

[0008] In one aspect, the intermediate plate aligns the second input shaft with the second lead screw.

[0009] In one aspect, the surgical instrument includes an articulation cable comprising a respective distal end coupled to the end effector and a respective proximal end coupled to one of the first nut and the second nut such that longitudinal translation of the first nut and the second nut causes articulation of the end effector.

[0010] In one aspect, the surgical instrument includes a first guide rod and a second guide rod disposed within the housing. The first guide rod is operably coupled to the intermediate plate and the first nut and is configured to inhibit rotation of the first nut relative to the first lead screw. The second guide rod is operably coupled to the intermediate plate and the second nut and is configured to inhibit rotation of the second nut relative to the second lead screw.

[0011] In one aspect, the articulation subassembly includes a third lead screw and a third nut. The third lead screw includes a gear portion, a waist portion, and an elongated threaded body portion. The gear portion of the third lead screw meshes with the distal gear portion of the proximal central gear, and the waist portion of the third lead screw is aligned with the proximal gear portion of the distal central gear. The third nut is threadedly engaged with the elongated threaded body portion of the third lead screw such that rotation of the third lead screw causes longitudinal translation of the third nut.

[0012] In one aspect, the articulation subassembly includes a fourth lead screw and a fourth nut. The fourth lead screw includes a gear portion and an elongated threaded body portion. The gear portion of the fourth lead screw meshes with the distal gear portion of the distal central gear. The fourth nut is threadedly engaged with the elongated threaded body portion of the fourth lead screw such that rotation of the fourth lead screw causes longitudinal translation of the fourth nut.

[0013] In one aspect, the surgical instrument includes a third guide rod and a fourth guide rod disposed within the housing. The third guide rod is operably coupled to the intermediate plate and the third nut and is configured to inhibit rotation of the third nut relative to the third lead screw. The fourth guide rod is operably coupled to the intermediate plate and the fourth nut and is configured to inhibit rotation of the fourth nut relative to the fourth lead screw.

[0014] In one aspect, the end effector includes a first jaw member and a second jaw member, wherein the first jaw member is movable relative to the second jaw member between an open position and a closed position to clamp tissue therebetween. Additionally, in one aspect, the gearbox assembly further includes a jaw drive subassembly operably coupled to at least one of the first jaw member or the second jaw member and configured to move the first jaw member relative to the second jaw member between the open position and the closed position.

[0015] In one aspect, the jaw drive subassembly includes a drive rod operably coupled to at least one of the first jaw member or the second jaw member and a spring force assembly releasably coupled to the drive rod. The spring force assembly includes a proximal hub defining an elongated hub shaft, a compression spring disposed about the elongated hub shaft, a distal hub disposed about a distal portion of the compression spring and movable relative to the proximal hub, and a locking plate slidably coupled to the proximal hub and configured to releasably lock the drive rod to the proximal hub.

[0016] In one aspect, the distal portion of the elongated hub shaft includes wings extending radially outward therefrom, and the distal hub defines a shelf configured to engage the wings to inhibit distal translation of the distal hub beyond the wings, thereby defining a maximum distance between the proximal hub and the distal hub.

[0017] In one aspect, the jaw drive subassembly includes an input shaft having an elongated threaded body portion threadedly engaged with the threaded bore of the distal hub such that rotation of the input shaft causes longitudinal translation of the distal hub.

[0018] In one aspect, the proximal hub includes a retainer guide and the distal hub includes a retainer guide. Each of the retainer guide of the proximal hub and the retainer guide of the distal hub is configured to be operably coupled to a guide rod to inhibit rotation of the distal hub relative to the proximal hub.

[0019] In one aspect, the spring force assembly is configured to maintain a clamping force between the first jaw member and the second jaw member during articulation of the end effector.

[0020] In one aspect, the proximal portion of the drive rod includes a key, and the locking plate defines a keyhole configured to receive the key to releasably secure the drive rod to the proximal hub.

[0021] According to various aspects of the present disclosure, a gearbox assembly for use with a surgical instrument is also provided, the gearbox assembly including an end effector having a first jaw member and a second jaw member. The gearbox assembly includes an articulation subassembly configured to articulate the end effector and a jaw drive subassembly configured to transition the end effector between an open position and a closed position. The articulation subassembly includes: a first lead screw including a gear portion, a waist portion, and an elongated threaded body portion; and a second lead screw including a gear portion and an elongated threaded body portion. A first nut is threadedly engaged with the elongated threaded body portion of the first lead screw, such that rotation of the first lead screw causes longitudinal translation of the first nut. A second nut is threadedly engaged with the elongated threaded body portion of the second lead screw, such that rotation of the second lead screw causes longitudinal translation of the second nut. The articulation subassembly also includes an intermediate plate including an intermediate plate rod extending proximally therefrom, and a proximal central gear and a distal central gear coupled to the intermediate plate rod. Each of the proximal center gear and the distal center gear includes a proximal gear portion and a distal gear portion. The distal gear portion of the proximal center gear meshes with the gear portion of the first lead screw. In addition, the distal gear portion of the distal center gear meshes with the gear portion of the second lead screw, and the proximal gear portion of the distal center gear is aligned with the waist portion of the first lead screw. In addition, the jaw drive subassembly includes a drive rod operably connected to at least one of the first jaw member or the second jaw member and a spring force assembly releasably connected to the drive rod. The spring force assembly includes: a proximal hub defining an elongated hub rod; a compression spring disposed around the elongated hub rod; a distal hub disposed around the distal portion of the compression spring and movable relative to the proximal hub; and a locking plate slidably coupled to the proximal hub and configured to releasably lock the drive rod to the proximal hub.

[0022] In one aspect, the spring force assembly is configured to maintain a clamping force between the first jaw member and the second jaw member during articulation of the end effector.

[0023] In one aspect, the gearbox assembly includes a guide rod operably coupled to the articulation subassembly and the jaw drive subassembly and configured to maintain alignment therebetween.

[0024] In one aspect, the articulation subassembly includes a first input shaft and a second input shaft. The first input shaft includes a gear portion that meshes with a proximal gear portion of the proximal sun gear, such that rotation of the first input shaft causes rotation of the proximal sun gear and the first lead screw. The second input shaft includes a first input shaft that includes a gear portion that meshes with the proximal gear portion of the proximal sun gear, such that rotation of the first input shaft causes rotation of the proximal sun gear and the first lead screw. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Various aspects and features of the disclosure are described below with reference to the drawings, wherein like numerals designate identical or corresponding elements in each of the several views.

[0026] Figure 1A is a perspective view of a surgical instrument provided in accordance with the present disclosure, the surgical instrument being configured to be mounted on a robotic arm of a surgical robotic system;

[0027] Figure 1B yes Figure 1A a rear perspective view of a proximal portion of a surgical instrument;

[0028] Figure 2 configured to releasably receive Figure 1A Schematic illustration of an exemplary robotic surgical system with a surgical instrument;

[0029] Figure 3 for Figure 1A a perspective view of a gearbox assembly of a surgical instrument with the housing removed;

[0030] Figure 4 yes Figure 1A A front perspective view of an articulated subassembly of a gearbox assembly of a surgical instrument;

[0031] Figure 5 yes Figure 4 a side perspective view of the hinge subassembly with some parts removed;

[0032] Figure 6 yes Figure 4 a side sectional view of a hinge subassembly;

[0033] Figure 7 yes Figure 4 a side sectional view of a hinge subassembly;

[0034] Figure 8 yes Figure 4 a top cross-sectional view of a hinge subassembly;

[0035] Figure 9 yes Figure 4a side sectional view of a hinge subassembly;

[0036] Figure 10 yes Figure 4 a bottom view of the hinge subassembly with some parts removed;

[0037] Figure 11 yes Figure 4 A top view of the hinge subassembly with some parts removed;

[0038] Figure 12 yes Figure 4 a top cross-sectional view of the hinge subassembly; and

[0039] Figure 13 yes Figure 4 A front sectional view of a hinge subassembly;

[0040] Figure 14 yes Figure 4 A front sectional view of a hinge subassembly;

[0041] Figure 15 yes Figure 4 a side view of a first drive screw of the hinge subassembly;

[0042] Figure 16 yes Figure 4 a side view of a second drive screw of the hinge subassembly;

[0043] Figure 17 yes Figure 4 a side view of a third drive screw of the hinge subassembly;

[0044] Figure 18 yes Figure 4 a side view of a fourth drive screw of the hinge subassembly;

[0045] Figure 19 yes Figure 1A A side view of a jaw drive assembly of a gearbox assembly of a surgical instrument;

[0046] Figure 20 yes Figure 19 a front perspective view of the jaw drive subassembly with some parts separated and additional components removed;

[0047] Figure 21 Is fixed to Figure 19 a front view of the proximal hub preceding the distal hub of the jaw drive subassembly;

[0048] Figure 22 Is fixed to Figure 19 a front view of the proximal hub behind the distal hub of the jaw drive subassembly;

[0049] Figure 23Before inserting the drive rod through the proximal hub Figure 19 A side sectional view of the jaw drive subassembly;

[0050] Figure 24 After inserting the drive rod through the proximal hub Figure 19 a side cross-sectional view of the jaw drive subassembly; and

[0051] Figure 25 After the drive rod is inserted through the proximal hub and secured there Figure 19 A side cross-sectional view of the jaw drive subassembly. DETAILED DESCRIPTION

[0052] refer to Figure 1A 、 Figure 1B 、 Figure 2 and Figure 3 The surgical instrument 10 provided in accordance with the present disclosure generally includes a housing 20, a shaft 30 extending distally from the housing 20, an end effector assembly 40 extending distally from the shaft 30, and a gearbox assembly 100 disposed within the housing 20 and operably associated with the end effector assembly 40. The instrument 10 is described herein as being configured for use with, for example, a robotic surgical system 1000 ( Figure 2 ) for use with a robotic surgical system. However, the aspects and features of the instrument 10 provided in accordance with the present disclosure, described in detail below, are equally applicable for use with other suitable surgical instruments and / or other suitable surgical systems.

[0053] Special References Figure 1A The housing 20 of the device 10 includes first and second body portions 22a, 22b and a proximal panel 24 that cooperate to connect the gearbox assembly 100 ( Figure 3 ) is enclosed in the middle. The proximal panel 24 includes holes defined therein, and the inputs 110, 120, 130, 140 ( Figure 1B ) extends through the hole to connect to the robotic surgical system 1000 ( Figure 2 A pair of latch rods 26 (only one of which is shown in FIG. 1 ) extend outwardly from opposite sides of the housing 20 and enable the housing 20 to be coupled to, for example, the robotic surgical system 1000 ( Figure 2 )'s robotic arm of a surgical system can be releasably engaged.

[0054] The shaft 30 of the instrument 10 includes a distal segment 32, a proximal segment 34, and an articulation segment 36 disposed between the distal segment 32 and the proximal segment 34. The articulation segment 36 includes one or more articulation assemblies 37, such as links, joints, etc. A plurality of articulation cables 38, such as four (4) articulation cables or other suitable actuators, extend through the articulation segment 36. More specifically, the articulation cables 38 are operably coupled at their distal ends to the distal segment 32 of the shaft 30 and extend proximally from the distal segment 32 of the shaft 30, through the articulation segment 36 of the shaft 30 and the proximal segment 34 of the shaft 30, into the housing 20, wherein the articulation cables 38 are operably coupled to the articulation subassembly 200 of the gearbox assembly 100 to selectively articulate the distal segment 32 (and thus the end effector assembly 40) relative to the proximal segment 34 and the housing 20, for example, about at least two articulation axes (e.g., yaw and pitch articulation).

[0055] With respect to articulation of the end effector assembly 40 relative to the proximal segment 34 of the shaft 30, the articulation cables 38 are actuated in pairs. More specifically, to tilt the end effector assembly 40, the upper pair of cables 38 are actuated in a similar manner, while the lower pair of cables 38 are actuated in a manner similar to each other but opposite to the upper pair of cables 38. With respect to yaw articulation, the right pair of cables 38 are actuated in a similar manner, while the left pair of cables 38 are actuated in a manner similar to each other but opposite to the right pair of cables 38.

[0056] Continue to refer Figure 1A The end effector assembly 40 includes a first jaw member 42 and a second jaw member 44, respectively. Each jaw member 42, 44 includes a proximal flange portion 43a, 45a and a distal body portion 43b, 45b, respectively. The distal body portions 43b, 45b define opposing tissue-contacting surfaces 46, 48, respectively. The proximal flange portions 43a, 45a are pivotally coupled to each other about a pivot axis 50 and are operably coupled to each other via a cam slot assembly 52, which includes a cam slidably received within a cam slot defined within the proximal flange portion 43a, 45a, respectively, of at least one of the jaw members 42, 44. This configuration enables the jaw member 42 to pivot relative to the jaw member 44 and the distal segment 32 of the shaft 30 between a spaced-apart position (e.g., an open position of the end effector assembly 40) and an approximated position (e.g., a closed position of the end effector assembly 40) for grasping tissue between the tissue-contacting surfaces 46, 48. As an alternative to this single-sided configuration, a double-sided configuration may be provided whereby the two jaw members 42 , 44 are pivotable relative to each other and the distal section 32 of the shaft 30 .

[0057] In various aspects, a longitudinally extending knife slot 49 (only the knife slot 49 of jaw member 44 is illustrated; the knife slot of jaw member 42 is similarly configured) is defined through tissue-contacting surfaces 46, 48, respectively, of jaw members 42, 44. In such embodiments, a knife assembly including a knife tube (not shown) extends from housing 20 through shaft 30 to end effector assembly 40, and a blade (not shown) disposed within end effector assembly 40 between jaw members 42, 44 provides for cutting tissue clamped between tissue-contacting surfaces 46, 48 of jaw members 42, 44, respectively.

[0058] Still refer to Figure 1A , a distal portion of the drive rod 484 is operably coupled to the cam slot assembly 52 of the end effector assembly 40, for example, by engaging a cam pin thereof, such that longitudinal actuation of the drive rod 484 causes the jaw member 42 to pivot relative to the jaw member 44 between a spaced apart position and an approximated position. More specifically, pushing the drive rod 484 causes the jaw member 42 to pivot proximally relative to the jaw member 44 toward an approximated (e.g., closed) position, while pushing the drive rod 484 causes the jaw member 42 to pivot distally relative to the jaw member 44 toward a spaced apart (e.g., open) position. However, other suitable mechanisms and / or configurations are also contemplated for pivoting the jaw member 42 relative to the jaw member 44 between a spaced apart position and an approximated position in response to selective actuation of the drive rod 484. The drive rod 484 extends proximally from the end effector assembly 40 through the shaft 30 and into the housing 20, wherein the drive rod 484 is operably coupled to the jaw drive subassembly 400 ( Figure 3 ) are coupled to enable selective actuation of the end effector assembly 40 to clamp tissue therebetween and apply a closing force within an appropriate jaw closing force range, as described in detail below.

[0059] Tissue-contacting surfaces 46, 48 of jaw members 42, 44, respectively, are at least partially made of a conductive material and are energizable to different electrical potentials to enable electrical energy to be conducted through tissue clamped therebetween. However, tissue-contacting surfaces 46, 48 may alternatively be configured to provide any suitable energy, such as heat, microwaves, light, ultrasound, ultrasonic waves, etc., through the tissue clamped therebetween for energy-based tissue treatment. Instrument 10 defines a conductive pathway (not shown) through housing 20 and shaft 30 to end effector assembly 40. The conductive pathway may include wires, contacts, and / or conductive components to enable tissue-contacting surfaces 46, 48 of jaw members 42, 44, respectively, to be electrically connected to an energy source (not shown), such as an electrosurgical generator, to provide energy to tissue-contacting surfaces 46, 48 to treat (e.g., seal) tissue clamped therebetween.

[0060] refer to Figure 3As described above, the gearbox assembly 100 is disposed within the housing 20 and includes the hinge subassembly 200, the knife drive subassembly (not shown), and the jaw drive subassembly 400. The hinge subassembly 200 is operatively coupled to the first and second inputs 110, 120 of the gearbox assembly 100 and the ( Figure 1B ) articulation cable 38( Figure 1A ) between them, so that upon receipt of appropriate input into the first and / or second inputs 110, 120, the articulated subassembly 200 manipulates the cable 38 ( Figure 1A ) to articulate the end effector assembly 40 relative to the longitudinal axis "L" defined by the shaft 30 in a desired direction, for example to pitch and / or yaw the end effector assembly 40.

[0061] The knife drive subassembly (not shown) is operably coupled to the fourth input 140 ( Figure 1B ) between the jaw members 42 and 44 and the knife tube (not shown), so that after receiving the correct input in the fourth input 140, the knife drive subassembly (not shown) causes the blade (not shown) to reciprocate between the clamping members 42 and 44 to cut the tissue grasped between the tissue contact surfaces 46 and 48.

[0062] The jaw drive subassembly 400 is operably coupled to the third input 130 ( Figure 1B ) and the drive rod 484, so that after receiving the correct input in the third input 130, the jaw drive subassembly 400 causes the jaw members 42, 44 to pivot between the spaced position and the approximated position to grasp the tissue therebetween and apply a closing force within the appropriate closing force range.

[0063] When the instrument 10 is mounted on the robotic surgical system 1000 ( Figure 2 ), the gearbox assembly 100 is configured to be coupled to the robotic surgical system 1000 ( Figure 2 ) are operably coupled to enable the mechanical operation of the gearbox assembly 100 to function as described above. That is, the robotic surgical system 1000 ( Figure 2 ) selectively provides inputs to the inputs 110, 12, 130, 140 of the gearbox assembly 100 to articulate the end effector assembly 40, grasp tissue between the jaw members 42, 44, and / or cut tissue grasped between the jaw members 42, 44. However, it is also contemplated that the gearbox assembly 100 is configured to interface with any other suitable surgical system, such as a manual surgical handle, a powered surgical handle, etc. For purposes herein, the robotic surgical system 1000 ( Figure 2 ) for description.

[0064] Steering Figure 2, the robotic surgical system 1000 is configured for use in accordance with the present disclosure. Aspects and features of the robotic surgical system 1000 that are not germane to an understanding of the present disclosure are omitted so as not to obscure the aspects and features of the present disclosure in unnecessary detail.

[0065] The robotic surgical system 1000 generally includes: a plurality of robotic arms 1002, 1003; a control device 1004; and an operating console 1005 coupled to the control device 1004. The operating console 1005 may include: a display device 1006, which may be specifically configured to display a three-dimensional image; and manual input devices 1007, 1008, through which a person (e.g., a surgeon) can remotely manipulate the robotic arms 1002, 1003 in a first operating mode. The robotic surgical system 1000 may be configured for minimally invasive operation on a patient 1013 lying on a patient table 1012. The robotic surgical system 1000 may further include a database 1014 specifically coupled to the control device 1004, in which preoperative data, such as from the patient 1013 and / or anatomical atlases, may be stored.

[0066] Each of the robotic arms 1002, 1003 may include a plurality of components connected by joints, and may be, for example, mounting devices for surgical tools "ST". One or more of the surgical tools "ST" may be instruments 10 ( Figure 1A ), thereby providing this functionality on the robotic surgical system 1000.

[0067] The robotic arms 1002 and 1003 may be driven by electric drives, such as motors, connected to a control device 1004. The control device 1004 (e.g., a computer) may be configured, particularly via a computer program, to activate the motors in such a manner as to cause the robotic arms 1002 and 1003 and their mounted surgical tools "ST" to perform desired movements and / or functions in accordance with corresponding inputs from manual input devices 1007 and 1008, respectively. The control device 1004 may also be configured in such a manner as to regulate the movement of the robotic arms 1002 and 1003 and / or the electric drives.

[0068] Reference Figures 3 to 18, shows the articulation subassembly 200 of the gearbox assembly 100, which generally includes a first input shaft 202, a second input shaft 204, a proximal plate 230, an intermediate plate 250, a proximal central gear 222, and a distal central gear 224. The articulation subassembly 200 also includes a first lead screw 302 threadedly coupled to a first nut 312, a second lead screw 304 threadedly coupled to a second nut 314, a third lead screw 306 threadedly coupled to a third nut 316, and a fourth lead screw 308 threadedly coupled to a fourth nut 318. Rotation of the lead screws 302, 304, 306, 308 effects longitudinal translation of the corresponding nuts 312, 314, 316, 318, which are coupled to corresponding articulation cables 38 ( Figure 1A ) to articulate the end effector assembly 40 relative to the longitudinal axis "L" defined by the shaft 30. In particular, each of the nuts 312, 314, 316, 318 includes a cable connector 312c, 314c, 316c, 318c for coupling to the proximal portion of each articulation cable 38 ( Figure 14 ).

[0069] The intermediate plate 250 includes an intermediate plate rod 255 extending proximally therefrom for supporting the proximal center gear 222 and the distal center gear 224. The proximal center gear 222 is rotatable about the intermediate plate rod 255 and includes a proximal gear portion 222p and a distal gear portion 222d. The proximal gear portion 222p and the distal gear portion 222d may have different diameters. The distal gear portion 222d of the proximal center gear 222 meshes with the gear portion 302g of the first lead screw 302. The distal center gear 224 is rotatable about the intermediate plate rod 255 and includes a proximal gear portion 224p and a distal gear portion 224d. The proximal gear portion 224p and the distal gear portion 224d may have different diameters. The distal gear portion 224d of the distal center gear 224 meshes with the gear portion 304g of the second lead screw 304. The proximal gear portion 224 p of the distal center gear 224 is aligned with the waist portion 302 w of the first lead screw 302 .

[0070] The first input shaft 202 includes a gear portion 202g that meshes with the proximal gear portion 222p of the proximal central gear 222, such that rotation of the first input shaft 202 causes rotation of the proximal central gear 222, and thereby causes rotation of the first lead screw 302. The second input shaft 204 includes a gear portion 204g that meshes with the proximal gear portion 224p of the distal central gear 224, such that rotation of the second input shaft 204 causes rotation of the distal central gear 224, and thereby causes rotation of the second lead screw 304.

[0071] The third lead screw 306 includes a gear portion 306g, a waist portion 306w, and an elongated threaded body portion 306t. The gear portion 306g of the third lead screw 306 meshes with the distal gear portion 222d of the proximal center gear 222, such that rotation of the proximal center gear 222 causes rotation of the third lead screw 306. The waist portion 306w of the third lead screw 306 is aligned with the proximal gear portion 224p of the distal center gear 224. As described above, the third nut 316 is threadedly engaged with the elongated threaded body portion 306t of the third lead screw 306. With this configuration, rotation of the third lead screw 306 causes longitudinal translation of the third nut 316 by virtue of rotation of the proximal center gear 222.

[0072] The fourth lead screw 308 includes a gear portion 308g and an elongated threaded body portion 308t. The gear portion 308g of the fourth lead screw 308 meshes with the distal gear portion 224d of the distal center gear 224, such that rotation of the distal center gear 224 causes rotation of the fourth lead screw 308. As described above, the fourth nut 318 is threadedly engaged with the elongated threaded body portion 308t of the fourth lead screw 308. With this configuration, rotation of the fourth lead screw 308, coupled with rotation of the distal center gear 224, causes longitudinal translation of the fourth nut 318.

[0073] As in Figure 8 As best shown in FIG, proximal plate 230 includes an alignment portion 231 for maintaining longitudinal alignment between first input shaft 202 and first lead screw 302. Similarly, intermediate plate 250 includes an alignment portion 251 for maintaining longitudinal alignment between second input shaft 204 and second lead screw 304.

[0074] The hinge subassembly 200 also includes guide rods 352, 354, 356, 358 that are used to maintain alignment between internal components coupled thereto and to prevent the nuts 312, 314, 316, 318 from rotating as the lead screws 302, 304, 306, 308 rotate. Specifically, a first guide rod 352 is disposed within the housing 20 and is operably coupled to the intermediate plate 250 and the first nut 312. During rotation of the first lead screw 302, the first guide rod 352 inhibits rotation of the first nut 312 relative to the first lead screw 302, thereby enabling the first nut 312 to translate longitudinally thereof. A second guide rod 354 is also disposed within the housing 20 and is operably coupled to the intermediate plate 250 and the second nut 314. The second guide rod 354 is configured to inhibit rotation of the second nut 314 relative to the second lead screw 304 during rotation of the second lead screw 302, thereby enabling the second nut 314 to translate longitudinally thereof. Additionally, a third guide rod 356 is disposed within the housing 20 and operably coupled to the intermediate plate 250 and the third nut 316. The third guide rod 356 is configured to inhibit rotation of the third nut 316 relative to the third lead screw 306 during rotation of the third lead screw 306, thereby enabling the third nut 316 to translate longitudinally thereof. Finally, a fourth guide rod 358 is also disposed within the housing 20 and operably coupled to the intermediate plate 250 and the fourth nut 318. The fourth guide rod 358 inhibits rotation of the fourth nut 318 relative to the fourth lead screw 308 during rotation of the fourth lead screw 308, thereby enabling the fourth nut 318 to translate longitudinally thereof.

[0075] Although described above as one guide rod coupled to one nut to inhibit rotation of the nut, more than one guide rod (e.g., two guide rods) may be coupled to a single nut to inhibit rotation of the single nut. For example, the first guide rod 352 and the second guide rod 354 may be operably coupled to the first nut 312 to inhibit rotation of the first nut 312, the second guide rod 354 and the third guide rod 356 may be operably coupled to the second nut 314 to inhibit rotation of the second nut 314, the third guide rod 356 and the fourth guide rod 358 may be operably coupled to the third nut 316 to inhibit rotation of the third nut 316, and the fourth guide rod 358 and the first guide rod 352 may be operably coupled to the fourth nut 318 to inhibit rotation of the fourth nut 318.

[0076] As described above, with respect to articulation of the end effector assembly 40 relative to the proximal segment 34 of the shaft 30, actuation of the articulation cables 38 is achieved in pairs. More specifically, to pitch the end effector assembly 40, the upper pair of cables 38 is actuated similarly relative to each other, while the lower pair of cables 38 is actuated similarly but oppositely relative to the upper pair of cables 38. With respect to yaw articulation, the right pair of cables 38 is actuated similarly relative to each other, while the left pair of cables 38 is actuated similarly but oppositely relative to the right pair of cables 38. This actuation (e.g., pulling or providing slack) of the articulation cables 38 is caused by rotation of the first and second input shafts 202, 204, which, through the gear coupling of the components of the articulation subassembly 200 described above, ultimately achieves longitudinal translation of each nut 312, 314, 316, 318, which is coupled to a corresponding proximal portion of the articulation cables 38.

[0077] As described above, the end effector assembly 40 includes a first jaw member 42 and a second jaw member 44, wherein the first jaw member 42 is movable between an open position and a closed position relative to the second jaw member 44 to grasp tissue therebetween. The jaw drive subassembly 400 is operably coupled to at least one of the first jaw member 42 or the second jaw member 44 and is configured to move the first jaw member 42 relative to the second jaw member 44 between the open position and the closed position.

[0078] Reference Figures 19-25 , shows the jaw drive subassembly 400 of the gearbox assembly 100, which generally includes an input shaft 410, a spring force assembly 450 operably coupled to the input shaft 410, and a drive rod 484 operably coupled to the input shaft 410 via the spring force assembly 450. In particular, a proximal portion of the drive rod 484 is coupled to the spring force assembly 450, and a distal portion of the drive rod 484 is coupled to one of the first jaw member 42 or the second jaw member 44, such that longitudinal translation of the spring force assembly 450 (or one or more components thereof) pushes or pulls the drive rod 484 to move at least one of the first jaw member 42 or the second jaw member 44 relative to the other. The spring force assembly 450 is configured to maintain a clamping force between the first jaw member 42 and the second jaw member 44 during articulation of the end effector assembly 40.

[0079] The input shaft 410 includes a shaft operatively coupled to the third input 130 ( Figure 1B) proximal portion 412 of the third input 130 such that rotation of the input shaft 410 results in rotation of the input shaft 410. That is, the rotational input provided to the third input 130 drives the rotation of the input shaft 410. The spring force assembly 450 is coupled to the input shaft 410 and includes a proximal hub 452, a distal hub 454, a compression spring 456, and a locking plate 482. The spring force assembly 450 may further include a guide rod 470, or alternatively may be coupled to any of the guide rods 352, 354, 356, 358 described above.

[0080] The proximal hub 452 includes a transverse slot 466 defined therethrough that is configured to receive a locking plate 482, as described in detail below, to secure the locking plate 482, and thereby secure the drive rod 484 relative to the proximal portion of the proximal hub 452 (see FIG. Figure 23-Figure 25 ). Once engaged in this manner, the drive rod 484 is locked in a position coaxially disposed through the proximal hub 452 and the distal hub 454. In particular, the proximal portion of the drive rod 484 includes a key 488, and the locking plate 482 defines a key hole 485 that is configured to receive the key 488 to releasably secure the drive rod 484 to the proximal hub 452.

[0081] A compression spring 456 is disposed about an elongated hub shaft 452s of the proximal hub 452. The distal hub 454 is disposed about a distal portion of the compression spring 456 and is movable relative to the proximal hub 452, with the biasing force provided by the compression spring 456 located therebetween. The distal portion of the elongated hub shaft 452s includes wings 452w extending radially outward therefrom, which are configured to engage with shelves 454s of the distal hub 454. With this configuration, distal translation of the distal hub 454 is inhibited beyond the wings 452w, thereby defining a maximum distance between the proximal hub 452 and the distal hub 454.

[0082] Reference Figure 21 and Figure 22 , the elongated hub shaft 452s of the proximal hub 452 is positioned through the opening defined by the distal hub 454 in a first orientation and is then rotated, for example, a quarter turn relative to the distal hub 454 to engage the shelves 454s of the distal hub 454 to the wings 452w of the proximal hub 452. The compression spring 456 provides an outward force against the distal hub 454 to maintain engagement between the shelves 454s of the distal hub 454 and the wings 452w of the proximal hub 452.

[0083] The elongated threaded body portion 414 of the input shaft 410 is threadedly engaged with the threaded bore 454t of the distal hub 454 such that rotation of the input shaft 410 causes longitudinal translation of the distal hub 454. Each of the retainer guide 452g of the proximal hub 452 and the retainer guide 454g of the distal hub 454 is operably coupled to the guide rod 470 to inhibit rotation of the distal hub 454 relative to the proximal hub 452 and maintain alignment therebetween as the input shaft 410 rotates.

[0084] In use, jaw members 42, 44 are initially positioned in the open position, and accordingly, proximal and distal hubs 452, 454 are positioned in the distal-most position, such that drive rod 484 is positioned in the distal-most position. Furthermore, in this position, compression spring 456 is positioned in a minimally compressed state; although, as described above, even in the minimally compressed state, compression spring 456 is partially compressed due to being held between proximal and distal hubs 452, 454.

[0085] In response to an input to close the end effector assembly 40, such as a rotational input to the third input 130, the input shaft 410 rotates, causing the distal hub 454 to translate toward the proximal hub 452. The proximal translation of the distal hub 454 forces the distal hub 454 against the compression spring 456. Initially, when the force resisting approximation of the jaw members 42, 44 is below a threshold corresponding to the spring value of the compression spring 456, the closing force applied by the jaw members 42, 44 is relatively low, causing the distal hub 454 to abut proximally against the compression spring 456 to urge the compression spring 456 proximally, which in turn urges the proximal hub 452 and the locking plate 482, thereby rotating the drive rod 484 proximally to pivot the first jaw member 42 relative to the second jaw member 44 from the spaced-apart position toward the approximated position to clamp tissue between the first and second jaw members.

[0086] As jaw members 42, 44 are further approximated to clamp tissue therebetween, the force resisting the approximation of jaw members 42, 44 (e.g., tissue resisting compression) may reach a threshold value, and thus the closing force applied by jaw members 42, 44 may reach a corresponding threshold value. To maintain the closing force applied by jaw members 42, 44 within a closing force range, e.g., approximately 3 kg / cm 2 To approximately 16kg / cm 2Within the range of φ 100, further application of closing force by jaw members 42, 44 is prevented beyond the stated point despite further rotational input to third input 130. More specifically, once the threshold is reached, further rotational input to third input 130 causes input shaft 410 to rotate, causing distal hub 454 to translate further proximally to compression spring 456. However, rather than compression spring 456 further urging proximal hub 452 proximally to continue approximating jaw members 42, 44 and increasing the closing force applied therebetween, compression spring 456 is compressed, enabling proximal hub 452, and therefore drive rod 484, to remain in position, thereby inhibiting application of additional closing force between jaw members 42, 44.

[0087] When tissue is clamped between jaw members 42, 44 under appropriate closing force, energy can be provided to jaw members 42, 44 to treat (eg, seal) the tissue. Subsequently, a blade (not shown) can be advanced between jaw members 42, 44 to cut the treated tissue.

[0088] Once the tissue has been cut or otherwise processed or grasped, an opposite rotational input is provided to the fourth input 140 to return the blade (not shown) to its initial position proximal to the main body portions 43b, 45b of the jaw members 42, 44 (see FIG. Figure 1A Thereafter, an opposite input is provided to third input 130 to return jaw members 42 , 44 toward the spaced-apart position to release the sealed, grasped, and / or cut tissue.

[0089] It should be understood that various modifications may be made to the various aspects disclosed herein. Therefore, the above description should not be interpreted as limiting, but merely as an illustration of various aspects. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.

[0090] It should be understood that the various aspects disclosed herein can be combined in combinations different from those specifically given in the description and drawings. It should also be understood that, depending on the examples, certain actions or events of any process or method described herein can be performed in different sequences, can be added, combined, or omitted entirely (e.g., all described actions or events may not be necessary to perform the technology). In addition, although certain aspects of the present disclosure are described as being performed by a single module or unit for clarity, it should be understood that the technology of the present disclosure can be performed by a combination of units or modules associated with, for example, a medical device.

[0091] In one or more embodiments, the described techniques may be implemented in hardware, software, firmware, or any combination thereof. If implemented in software, the functions may be stored as one or more instructions or codes on a computer-readable medium and executed by a hardware-based processing unit. A computer-readable medium may include a non-transitory computer-readable medium, which corresponds to a tangible medium, such as a data storage medium (e.g., RAM, ROM, EEPROM, flash memory, or any other medium that can be used to store desired program code in the form of instructions or data structures and that can be accessed by a computer).

[0092] Instructions may be executed by one or more processors, such as one or more digital signal processors (DSPs), general-purpose microprocessors, application-specific integrated circuits (ASICs), field-programmable logic arrays (FPGAs), or other equivalent integrated or discrete logic circuits. Thus, the term "processor," as used herein, may refer to any of the foregoing structures or any other physical structure suitable for implementing the described techniques. Furthermore, the techniques may be fully implemented in one or more circuits or logic elements.

Claims

1. A surgical instrument (10), comprising: Housing (20); a shaft (30) extending from the housing and defining a longitudinal axis ("L"); an end effector (40) operably coupled to the distal portion (32) of the shaft; and A gearbox assembly (100) disposed within the housing (20) and comprising an articulation subassembly (200) configured to articulate the end effector (40) about the longitudinal axis defined by the shaft (30), the articulation subassembly comprising: a first lead screw (302) comprising a gear portion (302g), a waist portion (302w), and an elongated threaded body portion; and a first nut (312) threadably engaged with the elongated threaded body portion of the first lead screw (302) such that rotation of the first lead screw effects longitudinal translation of the first nut; Characterized in that the hinge subassembly (200) further comprises: a second lead screw (304), the second lead screw comprising a gear portion (304g) and an elongated threaded body portion; a second nut (314) threadedly engaged with the elongated threaded body portion of the second lead screw (304) such that rotation of the second lead screw effects longitudinal translation of the second nut; an intermediate plate (250) including an intermediate plate rod (255) extending proximally therefrom; a proximal central gear (222) operably coupled to the intermediate plate rod (255) and rotatable about the intermediate plate rod, the proximal central gear comprising a proximal gear portion (222p) and a distal gear portion (222d), the distal gear portion of the proximal central gear meshing with the gear portion (302g) of the first lead screw (302); and A distal center gear (224) is operably connected to the intermediate plate rod (255) and is capable of rotating around the intermediate plate rod, the distal center gear including a proximal gear portion (224p) and a distal gear portion (224d), the distal gear portion of the distal center gear meshing with the gear portion (304g) of the second lead screw (304), and the proximal gear portion of the distal center gear is aligned with the waist portion (302w) of the first lead screw (302).

2. The surgical instrument according to claim 1, wherein: The hinge subassembly (200) comprises: a first input shaft (202) including a gear portion (202g) meshing with the proximal gear portion (222p) of the proximal sun gear (222) such that rotation of the first input shaft causes rotation of the proximal sun gear and the first lead screw; and A second input shaft (204) includes a gear portion (204g) meshing with the proximal gear portion (224p) of the distal sun gear (224) such that rotation of the second input shaft causes rotation of the distal sun gear and the second lead screw.

3. The surgical instrument according to claim 2, wherein: The articulation subassembly (200) includes a proximal plate (230) that aligns the first input shaft (202) with the first lead screw (302).

4. The surgical instrument according to claim 2, wherein: The intermediate plate (250) aligns the second input shaft (204) with the second lead screw (304).

5. The surgical instrument according to claim 1 further comprises an articulation cable (38), the articulation cable comprising a respective distal end coupled to the end effector (40) and a respective proximal end coupled to one of the first nut (312) and the second nut (314), such that longitudinal translation of the first nut and the second nut causes articulation of the end effector.

6. The surgical instrument according to claim 1, further comprising: a first guide rod (352) disposed within the housing (20) and operably coupled to the intermediate plate (250) and the first nut (312), the first guide rod being configured to inhibit rotation of the first nut relative to the first lead screw (302); and A second guide rod (354) is disposed within the housing (20) and is operably coupled to the intermediate plate (250) and the second nut (314), the second guide rod being configured to inhibit rotation of the second nut relative to the second lead screw (304).

7. The surgical instrument according to claim 1, wherein: The hinge subassembly (200) comprises: a third lead screw (306), the third lead screw comprising a gear portion (306g), a waist portion (306w), and an elongated threaded body portion, the gear portion of the third lead screw meshing with the distal gear portion (222d) of the proximal central gear (222), and the waist portion of the third lead screw aligned with the proximal gear portion (224p) of the distal central gear (224); and A third nut (316) is threadedly engaged with the elongated threaded body portion of the third lead screw (306) such that rotation of the third lead screw effects longitudinal translation of the third nut.

8. The surgical instrument according to claim 7, wherein: The hinge subassembly (200) comprises: a fourth lead screw (308), the fourth lead screw comprising a gear portion (308g) and an elongated threaded body portion, the gear portion of the fourth lead screw meshing with the distal gear portion (224d) of the distal center gear (224); A fourth nut (318) is threadably engaged with the elongated threaded body portion of the fourth lead screw (308) such that rotation of the fourth lead screw effects longitudinal translation of the fourth nut.

9. The surgical instrument according to claim 8, further comprising: a third guide rod (356) disposed within the housing (20) and operably coupled to the intermediate plate (250) and the third nut (316), the third guide rod being configured to inhibit rotation of the third nut relative to the third lead screw (306); and A fourth guide rod (358) is disposed within the housing (20) and is operably coupled to the intermediate plate (250) and the fourth nut (318), the fourth guide rod being configured to inhibit rotation of the fourth nut relative to the fourth lead screw (308).

10. The surgical instrument of claim 1 , wherein: The end effector (40) includes a first jaw member (42) and a second jaw member (44), the first jaw member being movable relative to the second jaw member between an open position and a closed position to clamp tissue therebetween; and The gearbox assembly (100) also includes a jaw drive subassembly (400) that is operably coupled to at least one of the first jaw member (42) or the second jaw member (44) and configured to move the first jaw member relative to the second jaw member between the open position and the closed position.

11. The surgical instrument according to claim 10, wherein: The jaw drive subassembly (400) comprises: a drive rod (484) operably coupled to at least one of the first jaw member (42) or the second jaw member (44); a spring force assembly (450) releasably coupled to the drive rod, the spring force assembly comprising: a proximal hub (452) defining an elongated hub shaft (452s); a compression spring (456) disposed about the elongated hub (452s); a distal hub (454) disposed about a distal portion of the compression spring (456) and movable relative to the proximal hub (452); and A locking plate (482) is slidingly coupled to the proximal hub (452) and is configured to releasably lock the drive rod (484) to the proximal hub.

12. The surgical instrument according to claim 11, wherein: The distal portion of the elongated hub rod (452s) includes wings (452w) extending radially outward therefrom, and the distal hub (454) defines a shelf (454s) configured to engage the wings to inhibit distal translation of the distal hub beyond the wings, thereby limiting a maximum distance between the proximal hub (452) and the distal hub (454).

13. The surgical instrument according to claim 11, wherein: The jaw drive subassembly (400) includes an input shaft (410) having an elongated threaded body portion threadedly engaged with a threaded bore (454t) of the distal hub (454) such that rotation of the input shaft causes longitudinal translation of the distal hub.

14. The surgical instrument according to claim 11, wherein: The proximal hub (452) includes a retainer guide (452g) and the distal hub (454) includes a retainer guide (454g), each of the retainer guide of the proximal hub and the retainer guide of the distal hub being configured to be operably coupled to a guide rod (470) to inhibit rotation of the distal hub relative to the proximal hub.

15. The surgical instrument according to claim 11, wherein: The spring force assembly (450) is configured to maintain a clamping force between the first jaw member (42) and the second jaw member (44) during articulation of the end effector (40).

16. The surgical instrument according to claim 11, wherein A proximal portion of the drive rod (484) includes a key (488), and the locking plate (482) defines a keyhole (485) configured to receive the key to releasably secure the drive rod to the proximal hub (452).

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