Robotic surgical system and drape for covering components of a robotic surgical system

Abstract

A drape for covering a robotic surgical system includes a proximal section joined to and continuous with a distal section. The distal section is fabricated from a relatively rigid material and is configured to cover more dynamic portions of the robotic surgical system, and the proximal section is fabricated from a light transmissive material and is configured to cover more static portions of the robotic surgical system.

Description

Background Technology

[0001] Robotic surgical systems have been used in minimally invasive medical procedures. Some robotic surgical systems include a console that supports a robotic surgical arm and surgical instruments (e.g., forceps or grasping tools) with at least one end effector mounted to the robotic surgical arm. The robotic surgical arm provides mechanical power to the surgical instruments for their operation and movement.

[0002] In robot-assisted medical procedures, various components of the robotic surgical system are typically covered to reduce the probability of unintentional contamination of the external surgical sterile area. Therefore, it would be beneficial to provide a component that allows for easier unfolding of the drape while reducing the probability of unintentional contamination of the external surgical sterile area. Summary of the Invention

[0003] According to one aspect of this disclosure, a cover sheet for covering a robotic surgical system is provided. The cover sheet includes a proximal segment and a distal segment, each defining a cavity therein. The cavity of the proximal segment is sized to receive at least a base portion of a surgical robotic arm, and the cavity of the distal segment is sized to receive a surgical assembly coupled to the surgical robotic arm. The proximal segment is made of a first material, and the distal segment is made of a second material that is more robust than the first material. The proximal and distal segments are joined together such that the cavity of the proximal segment abuts the cavity of the distal segment.

[0004] In all respects, the first material can be translucent, and the second material can be opaque.

[0005] In some aspects, the first material may be low-density polyethylene, and the second material may be polyurethane and / or ethylene methyl acrylate.

[0006] In other respects, the proximal and distal segments can be joined together with a medical-grade adhesive.

[0007] In other respects, the proximal segment may have an open and tubular distal end, and the distal segment may have an open and tubular proximal end that overlaps with the distal end of the proximal segment.

[0008] In all respects, the proximal segment and the distal segment can join each other at their respective distal and proximal ends.

[0009] In some respects, the first material can be thinner than the second material.

[0010] In other respects, the second material may have greater tensile strength, tear resistance and puncture resistance than the first material.

[0011] In other respects, the first material is more transparent than the second material.

[0012] In all respects, the distal segment may have a first zone and a second zone extending from the first zone. The first zone may be configured to cover multiple movable arms of the surgical robotic arm, and the second zone may be configured to cover the instrument drive unit and slider of the surgical assembly.

[0013] In some respects, the first zone may have a larger diameter than the second zone.

[0014] According to another aspect of this disclosure, a robotic surgical system is provided, comprising a surgical robotic arm, a surgical assembly, and a drape. The surgical robotic arm has a base portion and a plurality of movable parts coupled to the base portion. The surgical assembly is a first movable part coupled to the plurality of movable parts of the surgical robotic arm. The drape includes a proximal segment and a distal segment engaged with the proximal segment, each defining a cavity therein. The cavity of the proximal segment is sized to receive the base portion of the surgical robotic arm, and the cavity of the distal segment is sized to receive the surgical assembly and the movable parts of the surgical robotic arm. The proximal segment is made of a first material, and the distal segment is made of a second material different from the first material.

[0015] In all respects, the cavity in the proximal segment can be adjacent to the cavity in the distal segment.

[0016] Further details and aspects of exemplary embodiments of the present disclosure are described in more detail below with reference to the accompanying drawings.

[0017] As used herein, the terms parallel and perpendicular are understood to include substantially parallel and substantially perpendicular relative configurations that differ from true parallel and true perpendicular by at most approximately plus or minus 10 degrees. Attached Figure Description

[0018] Embodiments of this disclosure are described herein with reference to the accompanying drawings, in which:

[0019] Figure 1 This is a schematic diagram of a robotic surgical system, which includes a surgical robotic arm, a robotic surgical assembly coupled to the robotic arm, and a cover covering the surgical robotic arm and the robotic surgical assembly.

[0020] Figure 2 To illustrate the attachment to the robotic arm cart Figure 1 Perspective view of the robotic surgical assembly and robotic arm;

[0021] Figure 3 To illustrate the coverage Figure 1 The cover cloth Figure 2 Perspective view of the robotic surgical assembly and robotic arm;

[0022] Figure 4 To explain Figure 3 A perspective view of the tarpaulin; and

[0023] Figure 5 To explain Figure 4 Side view of the cover cloth. Detailed Implementation

[0024] Embodiments of the currently disclosed robotic surgical system are described in detail with reference to the accompanying drawings. The robotic surgical system includes a surgical robotic arm, a surgical assembly (including an instrument drive unit (“IDU”) and surgical instruments), and a drape for covering some or all of the aforementioned components, wherein the same reference numerals denote the same or corresponding elements in each of the several views. As used herein, the term “distal” refers to the portion of the surgical robotic arm, surgical assembly, or drape closer to the patient, while the term “proximal” refers to the portion of the surgical robotic arm, surgical assembly, or drape further away from the patient.

[0025] As will be described in detail below, a sterile, disposable, or reusable drape is provided for covering various components of a robotic surgical system. The drape maintains the sterility of the surgical assemblies and robotic arms housed therein. The drape also protects the robotic surgical system from the ingress of liquids and particles that could further damage the system. The drape is manufactured by joining two separate sheet materials together via an adhesive or any other suitable type of bonding. Each sheet material exhibits unique material properties, making each suitable for covering specific sections of the robotic surgical system.

[0026] First refer to Figures 1 to 3 For example, the surgical system of robotic surgical system 1 typically includes a robotic arm or robotic arm 2, 3 coupled to a robotic trolley 10, a surgical assembly 100 coupled to the surgical robotic arm 2, and a cover 200 for covering the robotic arm 2 and the surgical assembly 100. In some embodiments, the cover 200 may be sized to also cover the robotic arm trolley 10. The surgical assembly 100 includes an instrument drive unit (hereinafter referred to as "IDU") 110 coupled to a slide rail 40 of the surgical robotic arms 2, 3, and an electromechanical surgical instrument 130 operatively coupled to the IDU 110 via a sterile interface module 112 of the surgical assembly 100.

[0027] The surgical system 1 further includes a control device 4 and an operation console 5 coupled to the control device 4. The operation console 5 includes a display device 6 specifically configured to display three-dimensional images; and manual input devices 7, 8, which, by means of, a surgeon (not shown), can remotely operate the robotic arms 2, 3 in a first operating mode, as is known in principle to those skilled in the art. Each of the robotic arms 2, 3 may consist of a plurality of components 2a, 2b, 2c connected by couplings. A first component 2a is coupled to the surgical assembly 100, and a third component 2c is coupled to a base portion 42 of the surgical robotic arm 2. The base portion 42 may include a plurality of pivotable arms 44 configured to be detachably coupled to a trolley 10, and a display screen 46 coupled to one of the pivotable arms 44.

[0028] Robotic arms 2 and 3 can be driven by an electric actuator (not shown) connected to control device 4. Control device 4 (e.g., a computer) can be configured to specifically activate the actuator by means of a computer program, such that robotic arms 2 and 3, the attached robotic surgical assembly 100, and thus the electromechanical surgical instrument 130 (including an electromechanical end effector (not shown)) perform the desired movement according to the criteria defined by means of manual input devices 7 and 8. Control device 4 can also be configured to regulate the movement of robotic arms 2 and 3.

[0029] The robotic surgical system 1 is configured for use on a patient "P" lying on an operating table "ST" to be treated minimally invasively with surgical instruments, such as an electromechanical surgical instrument 130. In an embodiment, robotic arms 2, 3 may be coupled to a robotic arm trolley 10. Figure 2 Instead of the operating table "ST". The robotic surgical system 1 may also include more than two robotic arms 2, 3, which are also connected to the control unit 4 and remotely controlled by means of the operation console 5. For example, the surgical instruments of the electromechanical surgical instrument 130 (including an electromechanical end effector) may also be attached to the additional robotic arms.

[0030] Control device 4 can control multiple motors, such as motors (motor 1...n), each configured to drive movement of robotic arms 2, 3 in multiple directions. Furthermore, control device 4 can control the motor assembly (not explicitly shown) of the IDU 110 of the robotic surgical assembly 100 that drives various operations of the surgical instrument 130. In embodiments, each motor of IDU 110 can be configured to actuate a drive rod / cable or lever arm to achieve operation and / or movement of the electromechanical surgical instrument 130.

[0031] For a detailed discussion of the construction and operation of robotic surgical systems, please refer to U.S. Patent No. 8,828,023 entitled “Medical Workstation,” the entire contents of which are incorporated herein by reference.

[0032] refer to Figures 3 to 5 The cover 200 of the robotic surgical system 1 has a generally elongated configuration, such as a tubular shape, and typically includes a proximal segment 202 configured to cover a static portion of the surgical robotic system 1 and a distal segment 204 configured to cover a more dynamic portion of the surgical robotic system 1. The proximal segment 202 of the cover 200 has a tubular shape and defines an elongated cavity 206 therein, sized to accommodate a base portion 42 of the surgical robotic arm 2 (including arm 44 and display 46). The proximal segment 202 is made of a first material that is translucent to provide a clear view of the components of the surgical robotic system 1 (e.g., display 46) covered by the proximal segment 202. An exemplary material for the proximal segment 202 may be a light-transmitting and fluid-resistant low-density polyethylene. In other aspects, the first material of the proximal segment 202 may be high-density polyethylene (HDPE), polypropylene and / or polyethylene materials, or other similar non-toxic biocompatible compounds.

[0033] The proximal segment 202 may have a pair of handles 212a, 212b for guiding the drape 200 above the surgical robot system 1. The handles 212a, 212b may be attached to any suitable location on the drape 200. The proximal segment 202 of the drape 200 has an opening proximal end 202a and an opening distal end 202b that engage with or are coupled to an opening proximal end 204a of the distal segment 204.

[0034] The distal section 204 of the cover 200 has a tubular shape and an elongated cavity 208 therein, sized to accommodate components 2a, 2b, 2c of the surgical robotic arm 2 and the surgical assembly 100 (including the instrument drive unit 110 and the slider 40). The distal section 204 is made of a second material different from the first material of the proximal section 202. Because the distal section 204 is configured to cover more dynamic parts of the robotic surgical system 1 (e.g., movable arms 2a, 2b, 2c and IDU 110), a more robust material is chosen for the distal section 204 compared to the proximal section 202. Exemplary materials for the distal section 204 are polyurethane and / or ethylene methyl acrylate; however, other suitable materials are also considered. The material used to manufacture the distal section 204 is more resistant to tearing and puncture and exhibits greater tensile strength than the material used to manufacture the proximal section 202. Depending on the material used to form the distal segment 204, it can be opaque and therefore less translucent compared to the proximal segment 202.

[0035] Because the proximal segment 202 and the distal segment 204 are made of two different materials, each of which may have different melting temperatures, heat-sealing the proximal segment 202 and the distal segment 204 can be challenging. Therefore, the open and tubular distal end 202b of the proximal segment 202 and the open and tubular proximal end 204a of the distal segment 204 can be bonded, joined, or otherwise coupled to each other using medical-grade adhesives such as acrylic, cyanoacrylate, and / or epoxy resins. The proximal end 204a of the distal segment 204 can be disposed around the distal end 202b of the proximal segment 202, or the distal end 202b of the proximal segment 202 can be disposed around the proximal end 204a of the distal segment 204, and then joined to each other. In some respects, the proximal section 202 and the distal section 204 may be joined using any suitable fastening mechanism, such as glue, thermal bonding, ultrasonic welding, stitching, hook and loop fasteners, or seam bonding.

[0036] The distal segment 204 includes a first region 214 coupled to the proximal segment 202 and a second region 216 coupled to (e.g., via heat sealing) the first region 214 and extending distally from the first region 214. The first region 214 has a first diameter configured to surround the movable parts 2a, 2b, 2c of the surgical robotic arm 2 and a length sufficient to accommodate the parts 2a, 2b, 2c in a fully extended position. The second region 216 has a second diameter smaller than the first diameter of the first region 214 and is configured to surround the instrument drive unit 110 and the slider 40. The second region 216 may terminate at the most distal point of closure.

[0037] Zone 216 may have Enhancement Patch 220 ( Figure 5 The reinforcing patch 220 is positioned at the intended location of the instrument drive unit 110 when the drape 200 covers the robotic surgical system 1. The second region 216 defines an inlet or channel 218 in fluid communication with the cavity 206 of the proximal section 202. The inlet 218 has a sized sterile interface module 112 of the surgical assembly 100. Figure 3 The inlet 218 is generally annular in shape to form a liquid-tight seal when the aseptic interface module 112 is not used. In some aspects, the inlet 218 may be sized to form a liquid-tight seal with the distal portion of the instrument drive unit 110. The reinforcing patch 220 may be located at the distal end of the inlet 218 and / or substantially in the middle of the length along the second zone 216.

[0038] It is possible that the first material of the first region 214 of the cover 200 is relatively thinner than the second material of the second region 216 of the cover 200. Upon further consideration, the second material of the second region 216 of the cover 200 may have relatively greater tensile strength, tear resistance, and / or puncture resistance compared to the first material of the first region 214 of the cover 200.

[0039] During assembly, handles 212a and 212b are used to position the drape 200 above the guide rail 40 and instrument drive unit 110 to guide the drape 200 above the robotic surgical system 1. The proximal segment 202 of the drape 200 is guided above the base portion 42 of the surgical robotic arm 2, and a seal 203 between the proximal segment 202 and the distal segment 204 is positioned distally (e.g., forward) of the display 46. A first section 214 of the distal segment 204 is positioned above the movable parts 2a, 2b, and 2c of the robotic arm 2, and a second section 216 of the distal segment 204 is positioned above the slider 40 and instrument drive unit 110. A sterile interface module 112 is positioned as an inlet 218 extending through the distal segment 204 of the drape 200, through which surgical instruments 130 protrude from the drape 200. Latch 219, flexible strip 221, tie 223, clip, strap or any other suitable fastener may be used to attach selected sections of drape 200 to robotic surgical system 1 to ensure that drape 200 is held in place.

[0040] It should be understood that various modifications can be made to the embodiments disclosed herein. Therefore, the above description should not be construed as limiting, but rather as illustrative of various embodiments only. Those skilled in the art will envision other modifications within the scope and spirit of the appended claims.

Claims

1. A drape for covering a robotic surgical system, the drape comprising: a proximal section defining a cavity therein sized to receive at least a base portion of a surgical robot arm, the proximal section fabricated from a first material, the proximal section being tubular and defining a first diameter; and a distal section defining a cavity therein sized for receiving a surgical assembly coupled to the surgical robot arm, the distal section fabricated from a second material that is more robust than the first material, wherein the proximal section and the distal section are joined to one another such that the cavity of the proximal section is contiguous with the cavity of the distal section, the distal section being tubular and including: a first zone having a diameter equal to the first diameter of the proximal section; a second zone integral with and extending distally from the first zone, the second zone defining a second diameter that is less than the first diameter; and an inlet formed in a sidewall of the second zone of the distal section and in fluid communication with the cavity of the distal section, wherein the surgical assembly is connected to the surgical robot arm through the inlet such that the surgical assembly is external to the second zone of the distal section and the surgical robot arm is internal to the second zone of the distal section.

2. The drape of claim 1, wherein the first material is translucent and the second material is opaque.

3. The drape of claim 1, wherein the first material is low density polyethylene and the second material is at least one of polyurethane or ethylene methyl acrylate.

4. The drape of claim 1, wherein the proximal section and the distal section are joined to one another via a medical grade adhesive.

5. The drape of claim 1, wherein the proximal section has an open and tubular distal end and the distal section has an open and tubular proximal end that overlaps the distal end of the proximal section.

6. The drape of claim 5, wherein the proximal section and the distal section are joined to one another at their respective distal and proximal ends.

7. The drape of claim 1, wherein the first material is thinner than the second material.

8. The drape of claim 1, wherein the second material has greater tensile strength, tear resistance, and puncture resistance relative to the first material.

9. The drape of claim 1, wherein the first material is more optically transparent than the second material.

10. The drape of claim 1, wherein the first zone of the distal section is configured to cover a plurality of movable arms of the surgical robot arm and the second zone of the distal section is configured to cover an instrument drive unit and a sled of the surgical assembly.

11. A robotic surgical system comprising: a surgical robot arm including a base portion and a plurality of movable components coupled to the base portion; a surgical assembly coupled to a first movable component of the plurality of movable components of the surgical robot arm; and a drape including: a proximal section defining a cavity therein sized to receive at least a base portion of a surgical robot arm, the proximal section fabricated from a first material, the proximal section being tubular and defining a first diameter; and a distal section defining a cavity therein sized for receiving a surgical assembly coupled to the surgical robot arm, the distal section fabricated from a second material that is more robust than the first material, wherein the proximal section and the distal section are joined to one another such that the cavity of the proximal section is contiguous with the cavity of the distal section, the distal section being tubular and including: a first zone having a diameter equal to the first diameter of the proximal section; a second zone integral with and extending distally from the first zone, the second zone defining a second diameter that is less than the first diameter; and an inlet formed in a sidewall of the second zone of the distal section and in fluid communication with the cavity of the distal section, wherein the surgical assembly is connected to the surgical robot arm through the inlet such that the surgical assembly is external to the second zone of the distal section and the surgical robot arm is internal to the second zone of the distal section. a proximal section defining a cavity therein sized for receiving the base portion of the surgical robotic arm, the proximal section being fabricated from a first material, the proximal section being tubular and defining a first diameter; and a distal section joined to the proximal section, the distal section defining a cavity therein sized for receiving the surgical assembly and the plurality of movable components of the surgical robotic arm, the distal section being fabricated from a second material different from the first material, the distal section being tubular and including: a first zone having a diameter equal to the first diameter of the proximal section; a second zone integral with and extending distally from the first zone, the second zone defining a second diameter that is less than the first diameter; and an access port formed in a sidewall of the second zone of the distal section and in fluid communication with the cavity of the distal section, wherein the surgical assembly is connected to the surgical robotic arm through the access port such that the surgical assembly is located outside of the second zone of the distal section and the surgical robotic arm is located inside of the second zone of the distal section.

12. The robotic surgical system of claim 11, wherein the first zone of the distal section is configured to cover the plurality of movable components of the surgical robotic arm and the second zone of the distal section is configured to cover an instrument drive unit and a sled of the surgical assembly.

13. The robotic surgical system of claim 11, wherein the cavity of the proximal section is contiguous with the cavity of the distal section.

14. The robotic surgical system of claim 11, wherein the first material is thinner than the second material.

15. The robotic surgical system of claim 11, wherein the second material has greater tensile strength, tear resistance, and puncture resistance relative to the first material.

16. The robotic surgical system of claim 15, wherein the first material is more optically transparent than the second material.

17. The robotic surgical system of claim 11, wherein the first material is low density polyethylene and the second material is at least one of polyurethane or ethylene methyl acrylate.

18. The robotic surgical system of claim 11, wherein the proximal section and the distal section are joined to one another via a medical grade adhesive.

19. The robotic surgical system of claim 11, wherein the proximal section has an open and tubular distal end and the distal section has an open and tubular proximal end that overlaps the distal end of the proximal section.

Images