Driver module

Abstract

The present invention discloses a driver module for actuating ribs, the driver module comprising: a slider, the slider comprising a base portion, a rib storage portion and a main body portion, the rib storage portion is spaced apart from the base portion, and the main body portion extends from the base portion to the rib storage portion, the module further comprising a slider storage portion, the slider storage portion having a first end and a second end and being engageable with the base portion of the slider, so that the slider can be movably attached to the slider storage portion.

Description

[0001] The present invention relates to a driver module for actuating tendons, and in particular, but not exclusively, to a driver module for driving articulation of a surgical instrument by actuating a plurality of tendons. The tendons may be operated antagonistically in pairs, such that actuation of a first tendon in the pair causes a corresponding but opposite actuation of a second tendon in the pair. The present invention relates in particular to a driver module for actuating tendons, a surgical instrument comprising the driver module, a method of attaching tendons to a driver module while pre-tensioning the tendons, and a method of removably mounting a driver module to a motor module.

[0002] Surgical procedures require incisions to be made in order for the physician to access internal parts of the body. Minimally invasive surgery is a procedure that limits the size of the incision to reduce healing time, associated pain, and the risk of resulting wound infection. Therefore, minimally invasive surgery is preferred for the health of the patient. However, due to the reduced size of the incision, minimally invasive surgery was initially limited to relatively simple procedures.

[0003] In recent years, a variety of surgical instruments have been developed to enable physicians to perform increasingly complex procedures, such as minimally invasive surgery. Known surgical instruments include end effectors that enable certain actions required in surgical procedures to be performed, such as mechanical forceps, graspers, needle holders or scissors. The end effector can be connected to an articulated portion of the surgical instrument, which provides the end effector with multiple degrees of freedom, thereby enabling the end effector to perform the complex manipulations required for surgical procedures. The articulated portion can then be connected to a hollow shaft that allows the end effector to be positioned in a desired part of the body. The shaft can then be connected to a driver module of the surgical instrument, which provides inputs for controlling the end effector and the articulated portion. Therefore, the entire surgical instrument is capable of performing relatively complex surgical techniques.

[0004] The maximum width or diameter of known end effectors, articulated portions, shafts, and combinations thereof is small, typically less than 1 cm. However, these portions of known surgical instruments, and in particular the shaft, may extend over considerable lengths, typically exceeding 15 cm. The narrow width and extended length of the surgical instruments enable surgical techniques to be performed in the form of minimally invasive procedures.

[0005] Known surgical instruments such as those described above are of great benefit to surgical manipulation because they allow relatively complex surgical techniques to be performed in a minimally invasive manner.

[0006] However, there are problems with known surgical instruments of the type described above.

[0007] The end effector and articulated portion of known surgical instruments need to be articulated in a manner that does not affect the small size of the assembly. A known method of achieving this is to attach a first end of a tendon to different portions of the end effector and the articulated portion. The tendon then extends through the hollow shaft and a second end of the tendon is attached to some form of actuator in the driver module of the surgical instrument. Actuation of the tendon causes the end effector and the articulated portion to articulate.

[0008] Known drive modules are complex since they comprise a large number of moving parts in order to actuate the tendons with high precision.

[0009] Known driver modules are also expensive. The complexity and number of components required result in a high overall cost to manufacture the driver module. Due to the expense of the driver module, it needs to be used more than once to make it cost-effective. This leads to problems with sterility, as any part of the surgical instrument that may come into contact with the patient must be sterile.

[0010] Known driver modules suffer from a problem known as "kickback". When a rib is actuated, the portion of the surgical instrument to which the rib is attached moves in response to the actuation of the rib. In known driver modules, when the rib stops moving, the impulse provided by the actuation of the rib may not stop because the rib is flexible. As a result, the associated component of the surgical instrument may continue to move even though the actuation of the rib has stopped. As a result, the associated component of the surgical instrument is in a position different from where it was intended to be.

[0011] There are two negative effects of recoil. The first is that the physician controlling the surgical instrument may not be able to see the surgical instrument clearly, if at all, so it is very important that the surgical instrument is exactly where it is intended to be, otherwise it may cause harm to the patient. The second effect is that when the physician again controls the relevant part of the surgical instrument through new actuation of the tendons, there may be a certain period of "delay" between the actuation of the tendons and the movement of the relevant part. In other words, a certain amount of tendon actuation may be performed before the relevant part begins to move. This is caused by the need for the tendons to be re-tensioned before they can apply force to the relevant part. Again, this causes the surgical instrument to act differently than the controlling physician intended, which may cause the surgical instrument to move unexpectedly, thereby potentially harming the patient.

[0012] According to a first aspect of the present invention, there is provided a driver module for actuating a rib, the driver module comprising:

[0013] A slider, the slider comprising a base portion, a rib receiving portion and a main body portion, the rib receiving portion being spaced apart from the base portion and the main body portion and extending from the base portion to the rib receiving portion, the module further comprising a slider receiving portion, the slider receiving portion having a first end and a second end and being engageable with the base portion of the slider so that the slider can be movably attached to the slider receiving portion.

[0014] By means of the present invention, a rib can be actuated by movement of the slider. Because the base portion of the slider that can engage in the slider receiving portion is spaced apart from the rib receiving portion by the body portion, the rib receiving portion can be aligned with the rib to be controlled by the slider. At the same time, the base portion can be appropriately positioned to engage with the slider receiving portion to allow the slider to move.

[0015] This may be advantageous when the driver module forms part of a surgical instrument including a shaft through which a rib extends in order to operate the surgical instrument. In such embodiments of the invention, the rib can be easily received by the rib receiving portion of the slider without the need to steer the rib. This eliminates the need for additional components such as pulleys in order to properly guide the rib.

[0016] In such embodiments, the rib receiving portion may receive the end of the rib, which extends along the shaft and away from the shaft receiving portion. The end of the rib may also be secured to the rib receiving portion by any suitable means, such as crimping, glue, or solder. For example, in some embodiments of the present invention, the rib receiving portion itself may be crimped around the rib to hold the received end of the rib in place within the rib receiving portion.

[0017] In an embodiment of the present invention, the driver module includes a shaft receiving portion located toward the first end of the slider receiving portion, wherein the rib receiving portion is aligned with the shaft receiving portion.

[0018] In such embodiments of the invention, a rib extending along the shaft may exit the shaft and be received by the rib receiving portion without significant deflection.

[0019] In an embodiment of the present invention, the body portion of the slider further comprises an alignment portion adapted to position the rib receiving portion of the slider to be aligned with a shaft aperture.

[0020] In such embodiments of the invention, the base portion of the slider can engage the slider receiving portion at a position that is not aligned with the shaft aperture. The alignment portion can thus extend from the base portion and at least partially pass through the space between the slider receiving portion and the shaft aperture to align the rib receiving portion with the shaft aperture.

[0021] In an embodiment of the present invention, the slider comprises a driving portion extending from the base portion such that the base portion is positioned between the body portion and the driving portion.

[0022] In such embodiments of the invention, the drive portion of the slider may extend away from the body portion and away from the base portion of the slider. This arrangement may make the design of the driver module more efficient because the drive portion of the slider will not interfere with the rib receiving portion of the slider.

[0023] In an embodiment of the present invention, the slider receiving portion includes a channel extending at least partially along the length of the slider receiving portion between the first end and the second end, and the channel is suitable for receiving the base portion of the slider, whereby the base portion can be slidably moved within the channel.

[0024] In an embodiment of the invention, the channel is linear, but in other embodiments of the invention the channel may be, for example, curved.

[0025] In an embodiment of the invention, the channel is adapted to receive the base portion of the slider so that the base portion can slidably move within the channel. In other words, the movement of the slider is limited by the size of the channel and is typically linear, although as explained above, the movement may also follow a curved trajectory.

[0026] In embodiments of the invention, the channel may extend substantially from the first end of the slider receiving portion to the second end of the slider receiving portion. However, in other embodiments of the invention, the channel extends partially along the length of the slider receiving portion.

[0027] The drive module may further include a first roller having an axis and configured to be axially rotatable, the first roller being positionable so that the axis of the first roller is perpendicular to the base portion of the slider and engageable with the base portion of the slider so that movement of the slider causes the first roller to axially rotate.

[0028] In such embodiments of the invention, the first roller will provide support for the slider as it moves along the slider receiving portion. This can help minimize friction during movement of the slider.

[0029] The driver module may further include a second roller having an axis and configured to be axially rotatable, the first roller and the second roller being spaced apart from each other, the first roller being engageable with a first side of the base portion, and the second roller being engageable with a second side of the base portion.

[0030] In such embodiments of the present invention, the slider is supported at the first end and the second end during movement within the slider receiving portion.

[0031] This may provide additional support and further reduce friction during movement of the slide.

[0032] In an embodiment of the present invention, the driver module further includes a pretensioning actuator, which can move between a first position and a second position, wherein in the first position, the pretensioning actuator is engaged with the slider so that the slider is positioned toward the second end of the slider receiving portion, and wherein in the second position, the pretensioning actuator is disengaged from the slider; the driver module further includes a biaser, which biases the pretensioning actuator toward the first position.

[0033] In such embodiments, with the pretension actuator in the first position, the slider moves toward the second end of the slider receiving portion, away from the shaft receiving portion. Thus, ribs (extending along the shaft, away from the shaft, and received by the rib receiving portion of the slider) can be held in tension by the slider when the pretension actuator is biased toward moving the slider away from the shaft receiving portion and the associated shaft. This is advantageous when a surgical instrument is not in use, as maintaining tension within the ribs helps keep the ribs in good condition.

[0034] Alternatively, when the pretension actuator is in the second position, the slider is able to move freely up and down the slider receiving channel, which is advantageous when using the surgical instrument because the slider does not experience any resistance to movement that may negatively affect its actuation of the tendon.

[0035] In an embodiment of the invention, the driver module further comprises a deactivation device engageable with the pretensioning actuator and movable to a deactivated position, wherein the pretensioning actuator is configured to be in its second position.

[0036] In such embodiments, when the driver module is to be used, the deactivation device can be moved to its deactivated position, thereby configuring the pretensioning actuator to its second position to enable free movement of the slide. Movement of the deactivation device to its deactivated position can be inherently achieved when the driver module is engaged with the barrier to prepare for use of the surgical instrument.

[0037] In an embodiment of the present invention, the driver module includes a plurality of sliders, and each of the plurality of sliders is engageable with the slider receiving portion.

[0038] In such embodiments of the invention, the slider receiving portion includes a plurality of channels spaced apart from one another, each of the channels being engageable with one of the sliders.

[0039] In such embodiments of the invention, each slider would be engageable with one of the plurality of channels.

[0040] By the present invention, a plurality of ribs can be actuated by the movement of the plurality of sliders. Further, the plurality of ribs can include a pair of ribs coupled to each other so that the pair of ribs act against each other. In other words, if one of the pair of ribs is pulled in one direction, the other of the pair of ribs is thereby pulled in the opposite direction.

[0041] Thus, in some embodiments, each rib in a pair of antagonistic ribs may be attached to a corresponding slider of the plurality of sliders. A first slider of the sliders may be actuated in a first direction, thereby pulling its corresponding rib in the first direction. This in turn causes the paired ribs to travel in a second direction opposite to the first direction, thereby pulling a second slider attached to the rib in the second direction. Thus, multiple pairs of the plurality of sliders may work antagonistically to each other by actuating the ribs of the antagonistic pairs.

[0042] In an embodiment of the present invention, each channel will only be associated with a single slider. This means that in an embodiment of the present invention comprising multiple sliders, each slider can move within its own channel.

[0043] These channels may be linear, but in other embodiments of the invention they may be curved.

[0044] In such embodiments of the invention, each slider may include a body portion including an alignment portion adapted to position the rib receiving portion of the corresponding slider so that it is aligned with the shaft aperture. Thus, a plurality of ribs may extend along the shaft of the driver module, and each rib may exit the shaft and be received by a corresponding rib receiving portion without any rib having to be significantly turned away from the axis of the shaft.

[0045] This means that no additional components such as pulleys have to be used to properly route the tendons out of the shaft apertures in order for the tendons to reach their respective tendon receiving portions.

[0046] In an embodiment of the invention, the body portion of each slider comprises a head portion which is positionable such that the head portion of the slider can abut against the head portion of at least one other adjacent slider.

[0047] In such embodiments of the invention, the rib receiving portion of each of the sliders abuts or is close to the adjacent slider, so that the ribs exiting from the shaft aperture can be easily received by the corresponding rib receiving portion without having to turn to reach the rib receiving portion. Further, the sliders can rely on each other so that each slider supports the other sliders adjacent to it. This can reduce the impact of any forces acting on a single slider in use and improve the durability of the slider against bending or breaking.

[0048] In an embodiment of the present invention, the drive module may further include an attachment interface and a locking mechanism, wherein the attachment interface can engage with the mating interface, and the locking mechanism is suitable for locking the engagement between the attachment interface and the mating interface and unlocking the engagement between the attachment interface and the mating interface.

[0049] In such embodiments of the invention, the mating interface may be a mating interface forming part of a motor module for actuating the slider of the driver module, or a barrier for providing a sterility barrier between the driver module and a motor module.

[0050] In an embodiment of the present invention, the locking mechanism includes a latch, the latch including a wedge, and the latch is movable between a first position and a second position, wherein the wedge is received within the attachment interface in the first position and the wedge protrudes from the attachment interface in the second position, wherein the latch is biased toward the second position.

[0051] In such embodiments of the invention, the wedge can engage with a latch seat, for example, forming part of a barrier or motor module, when the attachment interface is engaged with the mating interface. For example, engagement of the wedge with the latch seat can lock the attachment interface into engagement with the mating interface, thereby locking the engagement of the driver module with the barrier or motor module.

[0052] In an embodiment of the present invention, the drive module may further include a gear assembly, which includes a gear slider capable of moving in a linear direction, a gear capable of rotating around a gear axis, and a geared shaft capable of rotating around a shaft axis, wherein the gear slider can engage with the gear; and the gear can engage with the geared shaft, so that the linear movement of the linear slider drives the gear to rotate around the gear axis, thereby rotating the geared shaft around the shaft axis.

[0053] In such embodiments of the invention, the geared shaft can be attached to or can form part of a shaft of a surgical instrument. The gear assembly can thus be used to convert linear movement of an actuator forming part of a motor module into rotational movement of, for example, the shaft of the surgical instrument.

[0054] According to a second aspect of the present invention, there is provided a surgical instrument comprising a driver module according to an embodiment of the present invention, the driver module comprising a single slider, and the surgical instrument further comprising: a rib, the rib being receivable at a first end by the rib receiving portion of the slider;

[0055] an articulation module operably connectable to the rib;

[0056] a shaft extending from the driver module to the hinge module, wherein the rib extends through the shaft;

[0057] an end effector operably connected to the rib; and

[0058] A motor module includes an actuator that is movable and operatively engageable with the slider such that movement of the actuator causes movement of the slider.

[0059] According to a further aspect of the present invention, there is provided a surgical instrument comprising a driver module according to an embodiment of the present invention, the driver module comprising a plurality of sliders and further comprising a plurality of ribs, each of the ribs being receivable at a first end by a rib receiving portion of one of the plurality of sliders;

[0060] a shaft extending from the driver module, the plurality of ribs extending through the shaft;

[0061] an articulation module operatively coupled to the shaft and attachable at a second end thereof to one or more of the plurality of ribs;

[0062] an end effector operatively coupled to the articulation module and attachable at a second end thereof to one or more of the tendons; and

[0063] A motor module includes a plurality of actuators, each of the actuators being movable and engageable with the plurality of sliders such that movement of the actuator provides movement of one of the plurality of sliders.

[0064] In an embodiment of the present invention, the surgical instrument further comprises a barrier having a first side and a second side, the first side being engageable with the driver module and the second side being engageable with the motor module.

[0065] In such embodiments, the barrier is sterile along all sides before the barrier is provided to the surgical instrument for use. However, in use, the second side engages with the non-sterile motor module, so the second side of the barrier becomes non-sterile while the first side remains sterile because it is protected by the barrier and does not come into contact with non-sterile components. This means that the motor module, which may be expensive, does not need to be sterilized after each use. This may be useful because the motor module may include various electrical components that may be damaged during sterilization.

[0066] In an embodiment of the present invention, the barrier comprises a plurality of barrier sliders, each of the plurality of barrier sliders comprises a first portion and a second portion, the first portion being engageable with one of the plurality of sliders of the driver module, and the second portion being engageable with one of the plurality of actuators of the motor module.

[0067] In such embodiments, all portions of the plurality of barrier sliders are sterile before the barrier is provided to the surgical instrument for use. In use, the second portion of each barrier slider may become non-sterile after engaging one of the plurality of actuators of the non-sterile motor module. However, the first portion remains sterile because it is protected by the barrier. This again means that the motor module does not need to be sterilized after each use. This may be useful because the motor module may include various electrical components that may be damaged during sterilization.

[0068] In an embodiment of the present invention, the mating interface is a barrier interface forming part of the first side of the barrier and includes a latch seat, the wedge can be received in the latch seat when the attachment interface is engaged with the barrier interface, and the wedge is adapted so that, when the attachment interface is engaged with the barrier interface, the bias of the latch toward the second position biases the driver module toward a position in which the plurality of sliders are engaged with the plurality of barrier sliders and the plurality of ribs are tensioned.

[0069] In such embodiments of the invention, the wedge may be adapted, for example, to have a tapered shape, such that when the wedge moves toward the second position (to its biased position), the wedge causes the attachment interface to move over the barrier interface until each of the plurality of sliders contacts a respective barrier slider. This may place the tendons attached to each slider under tension and reduce backlash in the surgical instrument. Thus, the wedge may be adapted to provide optimal engagement of the attachment interface with the barrier interface.

[0070] The invention will now be described, by way of example only, with reference to the accompanying drawings, in which:

[0071] Figure 1 is a diagram of a slider according to an embodiment of the first aspect of the present invention, the embodiment comprising a base portion and a rib receiving portion and a body portion.

[0072] Figure 2 is a diagram of a driver module according to another embodiment of the first aspect of the present invention, the embodiment comprising a Figure 1 The slider and slider storage portion shown in .

[0073] Figure 3 is a diagram of a driver module according to a further embodiment of the first aspect of the present invention, this embodiment comprising a first roller and a second roller.

[0074] Figure 4 is a diagram of a driver module according to a further embodiment of the first aspect of the present invention, the embodiment comprising a plurality of sliders.

[0075] Figure 5 is an illustration of a driver module according to a further embodiment of the first aspect of the present invention, the embodiment comprising a shaft receiving portion, a locking mechanism and a gear mechanism.

[0076] Figure 6 yes Figure 5 00147] An illustration of the gear mechanism shown in FIG. 10, which is shown here removed from the drive module.

[0077] Figure 7 is a cross-sectional perspective view of a driver module according to a further embodiment of the first aspect of the invention, the embodiment comprising a pretensioning actuator.

[0078] Figure 8 yes Figure 7 , which shows a driver module in a first position.

[0079] Fig. 9 yes Figure 7, which shows the pretensioning actuator in the second position.

[0080] Fig.10 is a diagram of a driver module according to a further embodiment of the first aspect of the present invention, the embodiment comprising a device similar to Figure 5 A barrier according to an embodiment of the second aspect of the present invention is also shown.

[0081] Fig.11 yes Fig.10 An illustration of a driver module is shown showing the internal components of the locking mechanism.

[0082] Fig.12 yes Fig.10 A cross-sectional view of a driver module is shown, wherein the driver block module and Fig.10 The barrier engagement shown.

[0083] Fig.13 is an illustration of a driver module according to a further embodiment of the first aspect of the invention, the embodiment comprising a pull ring.

[0084] Fig.14 is a diagrammatic representation of a barrier according to a further embodiment of the second aspect of the present invention.

[0085] Fig.15 yes Fig.11 , which shows a barrier slider.

[0086] Fig.16 is a diagram of a surgical instrument according to an embodiment of the second aspect of the present invention, the surgical instrument comprising Figure 6 Drive modules, axes, articulation modules, and end effector shown.

[0087] Fig.17 is an illustration of a surgical instrument according to a further embodiment of the second aspect of the present invention, the surgical instrument comprising a driver module, a shaft, a barrier and a motor module.

[0088] Initially, first refer to Figure 1 The slider according to an embodiment of the first aspect of the present invention is generally indicated by reference numeral 4. The slider 4 comprises a base portion 10 and a rib receiving portion 20 spaced apart from the base portion 10. The base portion 10 comprises a first end 11, a second end 12, a first side 15 and a second side 16.

[0089] The slider further includes a body portion 22 extending from the base portion 10 to the rib receiving portion 20 and a driving portion 30. The base portion 10 is positioned between the body portion 22 and the driving portion 30. The body portion 22 includes an alignment portion 24 and a head portion 26.

[0090] Reference now Figure 2 According to another embodiment of the first aspect of the present invention, a driver module is generally indicated by reference numeral 2. The driver module 2 includes a slider 104 and a slider receiving portion 6. The slider 104 and Figure 1 The slider 4 shown is similar and interchangeable. All of the features of the slider 104 correspond to similar or identical features in the slider 4, so for ease of reference, the reference numerals used for the slider 4 also apply to the slider 104.

[0091] The slider receiving portion 6 includes a first end 7 and a second end 8. The slider receiving portion 6 is engageable with the base portion 10 of the slider 104 such that the slider 104 is movably attached to the slider receiving portion 6.

[0092] The driver module 2 further includes a guide tray 40, which includes a slider receiving portion 6. The slider receiving portion 6 includes a plurality of channels 42, each extending along the length of the slider receiving portion. However, in this embodiment of the invention, only one channel 42 is required to engage with the slider 4. The channel 42 is adapted to receive the base portion 10 of the slider 104 so that the slider can move along the channel 42. In some embodiments of the invention, the slider receiving portion 6 may include only a single channel 42. In this embodiment of the invention, the channel 42 is linear, but in other embodiments of the invention, it may follow a different trajectory.

[0093] Reference now Figure 3 , a driver module according to a further embodiment of the first aspect of the present invention is generally indicated by reference numeral 102. The driver module 102 includes a slider 104 and a slider receiving portion 106. The slider receiving portion 106 includes a first end 107 and a second end 108. The slider receiving portion 106 is engageable with the base portion 10 of the slider 104 so that the slider 104 is movably attached to the slider receiving portion 6.

[0094] The driver module 102 further includes a guide tray 140, which includes a slider receiving portion 106. The slider receiving portion 106 includes a plurality of channels 142, which are similar to Figure 2 The embodiment of the present invention is shown.

[0095] The driver module 102 further includes a first roller 146 and a second roller 148 spaced apart from each other. Both the first roller 146 and the second roller 148 are engageable with the base portion 10 of the slider 4. The first roller is positioned to engage the slider 104 from the first side 15 of the base portion 10 and near the first end 11. The second roller is positioned to engage the slider 104 from the second side 16 of the base portion 10 and near the second end 12.

[0096] The respective positions of the first and second rollers 146, 148 mean that, in use, the slider 104 remains engaged within the slider receiving portion 106. The first and second rollers 146, 148 are rotatable about their respective axes to facilitate movement of the slider 104 toward and away from the first end 107 of the slider receiving portion 106.

[0097] In other words, the linear movement of the slider 104 is converted into rotational movement of the first roller 146 and the second roller 148. Where the linear movement of the slider may otherwise have caused sliding friction between the slider 104 and any contact surface, in this embodiment of the invention, at least some of the contact pressure exhibited by the slider in use is transferred from the slider 104 to the first roller 146 and the second roller 148. The first roller 146 and the second roller 148 can be configured to experience minimal friction when rotating about their respective axes. Thus, in use, when the slider 104 moves toward or away from the first end 107, the movement is facilitated by the first roller 146 and the second roller 148 with minimal friction.

[0098] Reference now Figure 4 A driver module according to another embodiment of the first aspect of the present invention is generally indicated by reference numeral 202. The driver module 202 includes a plurality of sliders 4 and a slider receiving portion 206. The slider receiving portion 206 is engageable with the base portions 10 of the plurality of sliders 4 so that each slider 4 is movably attached to the slider receiving portion 206.

[0099] The driver module 202 further includes a guide tray 240 including a slider receiving portion 206. The slider receiving portion 206 includes a plurality of linear channels 242 that are evenly spaced across the guide tray 240. Each of the plurality of linear channels 242 is adapted to receive the base portion 10 of a corresponding slider 4 so that the base portion 10 of each slider 4 can move along the corresponding linear channel 242.

[0100] The alignment portion 24 of each of the plurality of sliders 4 is adapted to place the rib receiving portion 20 of each slider 4 in close alignment with each other. To achieve this, the alignment portion 24 of each slider 4 is configured according to the position of the corresponding channel 242 that the slider 4 can engage. Therefore, the first slider 4a has an alignment portion 24a, which has a size and / or shape different from the alignment portion 24b of the second slider 4b. There are differences in the shape of the alignment portion 24 on each of the plurality of sliders 4. In an embodiment of the present invention, the shape of the alignment portion 24 may vary due to changes in its length, angle, orientation, or any combination thereof. In other embodiments of the present invention, the shape of the alignment portion 24 may vary due to significantly different geometric shapes. In other embodiments of the present invention, the shape of the alignment portion 24 may remain unchanged.

[0101] The alignment portion 24 of each slider 4 is further adapted to position the head portion 26 of each slider in close proximity or abutment with the head portion 26 of at least one other adjacent slider 4 of the plurality of sliders.

[0102] exist Figure 4 In the illustrated embodiment, adjacent head portions 26 abut against each other. The head portion 26 of each slider 4 is adapted to slidably abut against the head portion 26 of at least one adjacent slider 4 of the plurality of sliders 205. The sliders 4 are thus able to slide past each other while also abutting against at least one adjacent slider. The abutment of the head portions 26 against each other provides support for the sliders 4 from the other sliders 4. This support is substantially perpendicular to the direction of the plurality of linear channels 244 and perpendicular to the base portion 10 of each of the plurality of sliders 205. Providing support in this direction protects the sliders 4 from twisting or bending in response to forces that may be transmitted during actuation of the drive portion 30 of each of the plurality of sliders 205.

[0103] Reference now Figure 5 A driver module according to another embodiment of the first aspect of the present invention is generally indicated by reference numeral 302. The driver module 302 includes Figure 4 and further includes a plurality of ribs 301 , a shaft 303 , a shaft receiving portion 313 , an attachment interface 350 , a locking mechanism 352 , and a gear assembly 370 .

[0104] The gear assembly includes a geared shaft 378. The shaft receiving portion 313 is adapted to receive the geared shaft 378 such that the geared shaft 378 is rotatably attached to the shaft receiving portion 313. The geared shaft is further adapted to receive the shaft 303 such that the shaft 303 is non-rotatably attached to the geared shaft 378.

[0105] A plurality of ribs 301 extend through the shaft 303, the geared shaft 378, and the shaft receiving portion 313. Each of the ribs 301 is received by the corresponding rib receiving portion 20 at a first end.

[0106] The alignment portion 24 of each of the plurality of sliders 4 is adapted to position the rib receiving portions 20 of the sliders 4 to be closely aligned with each other, as described above with respect to Figure 4 In this embodiment, this also keeps the rib receiving portion 20 in close axial alignment with the shaft receiving portion. Thus, the ribs 301 extending through the shaft 303 remain generally aligned as they extend out of the shaft receiving portion 313 toward the corresponding rib receiving portion 20.

[0107] Maintaining the plurality of ribs 301 substantially aligned with the shaft 303 eliminates the need to use pulleys or any other means to divert the ribs 301 to reach the rib receiving portion. This in turn reduces the number of components required in the driver module 302 and also reduces the potential for wear of the plurality of ribs 301.

[0108] The attachment interface 350 is engageable with a barrier, which in turn is engageable with the motor module. The locking mechanism 352 is adapted to respectively lock and unlock the attachment interface 350 into engagement with the barrier and out of engagement with the barrier.

[0109] Reference now Figure 6 , showing in more detail Figure 5 The gear assembly shown in FIG. The gear assembly includes a gear slider 372 and a gear 374. The gear slider 372 can move in a linear direction, the gear 374 can rotate about its central axis, and the geared shaft 378 can rotate about its central axis. Figure 5 The shaft 303 shown shares the central axis. The gear slider 372 can engage with the gear 374, which in turn can engage with the geared shaft 378. The linear movement of the linear slider 372 drives the gear 374 to rotate about its axis, which in turn drives the geared shaft 378 to rotate about its axis. Figure 5 When the shaft 303 shown in FIG. 3 is non-rotatably attached to the geared shaft 378 , the linear movement of the gear slider 372 drives the geared shaft 378 to rotate about its axis, which in turn rotates the shaft 303 .

[0110] Reference now Figure 7, a driver module according to another embodiment of the first aspect of the present invention is generally indicated by reference numeral 402. A cross-sectional view of the driver module 402 is shown, and the driver module includes a plurality of sliders 404, a pretensioning actuator 460, and a disengagement device 464. The pretensioning actuator includes a biasing element 461 and a cross plate 462. The disengagement device 464 includes a lever pin 466 about which the disengagement device can rotate. The lever pin can be attached to a guide tray, thereby anchoring the disengagement device in the driver module 402. (The guide tray is not shown here, but can be considered equivalent to Figure 2 , 3 , 4 and 5 shown in the guide tray 40, 140 and 240)

[0111] Reference now Figure 8 , shows a cross section of the driver module 402. The pretension actuator 460 is shown in a first position in which it is engaged with the plurality of slide blocks 404 via a cross-plate 462.

[0112] The biasing element 461 takes the form of a spring in this embodiment of the invention. The biasing element biases the pretensioning actuator toward the second end 8 of the slider receiving portion (not shown). While moving toward the second end 8 of the slider receiving portion 6, the pretensioning actuator 460 contacts and engages the plurality of sliders 404. The pretensioning actuator 460 continues to move toward the second end 8 of the slider receiving portion, and in doing so provides movement of the plurality of sliders 404 in the same direction. This continues until the plurality of ribs are fully tensioned and the plurality of sliders 5 cannot move further. (The plurality of ribs are not shown here, but may be considered equivalent to Figure 5 Therefore, a pre-tensioning actuator 460 is provided to maintain the tension of the plurality of tendons, which helps to keep the plurality of tendons 401 in a good condition.

[0113] Reference now Fig. 9 ,and Figure 8 Similarly shown is a cross section of the driver module 402. The pretension actuator 460 is shown in a second position where the cross-plate 462 is disengaged from the plurality of slide blocks 404.

[0114] The pretensioning device 460 can be moved to the second position by rotating the disengaging device 464 about the lever pin 466 so that it is disengaged from the Figure 8 The position shown changes to Fig. 9The position shown. Rotation of the disengagement device 464 acts on the biasing element 461, in this embodiment by compressing the spring. When in the second position, the pretensioning device 460, in particular the cross plate 462, is disengaged from the plurality of sliders 404. This provides the plurality of sliders with the ability to move freely in the corresponding slider channels (not shown) toward the first end 7 or the second end 8 of the slider receiving portion. In this embodiment of the invention, the plurality of sliders 404 are able to move 4 mm in either direction when the pretensioning actuator 460 is disengaged.

[0115] In use, the driver module 402 engages the barrier via the attachment interface 450. Figure 8 The disengagement device 464 in the position shown protrudes from the surface of the attachment interface 450 so that when the driver module 402 is engaged with the barrier, the disengagement device 464 is moved about the lever pin 466 toward the Fig. 9 This rotation of the disengagement device 464 causes the pretensioning actuator 460 to move from the first position to the second position against the bias of the biasing element 461 .

[0116] This means that when the driver module 402 is engaged with the barrier, ready for use, the disengagement device 464 automatically disengages the pretensioning actuator 460 from the plurality of sliders 404 , allowing the sliders 404 to move freely without pressure being applied thereagainst by the biasing element 461 .

[0117] Reference now Fig.10 A surgical instrument according to an embodiment of the second aspect of the present invention is generally indicated by reference numeral 500. The surgical instrument comprises a driver module 502, a shaft 503 and a barrier 580.

[0118] The driver module 502 includes an outer housing 590, a shaft receiving portion 513, an attachment interface 550, a locking mechanism 552, and a handle 559, while the barrier 580 includes a barrier interface 581. The driver module 502 is positioned so that the attachment interface 550 is ready to engage with the barrier interface 581 of the barrier. The barrier interface 581 is an example of a mating interface that the attachment interface 550 can engage. The attachment interface 550 can engage with any suitable mating interface, another example being a mating interface that forms part of a motor module for actuating a slider of the driver module 502.

[0119] The barrier interface 581 includes a pair of barrier grooves 582 extending along the length of the barrier interface 581, and the attachment interface 550 includes a pair of attachment ridges 551 extending along the length of the attachment interface 550 and receivable by the barrier grooves 582. In use, the attachment interface 550 can be engaged with the barrier interface 581 by grasping the handle 559 and simply sliding the attachment interface 550 into contact with the barrier interface 581 so that the attachment ridges 551 are fully received by the barrier grooves 582.

[0120] The shaft 503 is engaged with the shaft receiving portion 513 .

[0121] Reference now Fig.11 , which illustrates Fig.10 Driver module 502 is shown in FIG. 5 with exterior housing 590 and attachment interface 550 removed to reveal internal components of locking mechanism 552 .

[0122] In this embodiment of the present invention, the locking mechanism 552 includes a pair of latches 554, a pair of springs 557, and a release handle 558. The pair of latches 554 are spaced apart from each other and extend vertically from the release handle 558, parallel to each other. Each latch 554 includes a piston 555 at a proximal end and a wedge 556 at a distal end. Further, each latch 554 is coupled to the release handle 558 at its proximal end, wherein the piston 555 extends from the release handle 558, and the release handle is shaped as a cylindrical rod surrounded by a corresponding spring in the springs 557. The wedge 556 further extends from the piston 555 in a wedge shape that tapers toward the distal end of the latch 554.

[0123] Reference now Fig.12 , provides Fig.10 502 and barrier 580, wherein the driver module 502 is engaged with the barrier 580. Only a single latch 554 and corresponding spring 557 can be seen here, but the second latch and spring are still present. Therefore, the following discussion of Fig.12 The description of the latch 554 and spring 557 shown in also applies to the latch 554 and spring 557 not shown.

[0124] The latch 554 and corresponding spring 557 are enclosed in the attachment interface 550. A first end of the spring 557 is attached to the latch 554, and a second end is attached to the attachment interface 550. Movement of the latch 554 in the direction of its proximal end relative to the attachment interface compresses the spring 557, so that the wedge 556 of the latch 554 is biased by the spring 557 toward protruding from the attachment interface 550.

[0125] When engaging the driver module 502 with the barrier 580, the attachment interface 550 slides over the barrier interface 581 so that the attachment ridge 551 is received by the barrier groove 582, as described above. However, when the attachment interface 550 slides over the barrier interface 581, the wedge 556 protrudes from the attachment interface and abuts against the leading edge 583 of the barrier interface 581. Therefore, the complete reception of the attachment ridge 551 into the barrier groove is hindered.

[0126] The wedge 556 and the leading edge 583 are adapted so that the abutting surfaces of the leading edge 583 and the wedge 556 are at complementary angles to each other. Once the wedge 556 abuts the leading edge 583, further linear sliding movement of the attachment interface relative to the barrier interface 581 forces the latch in the direction of its proximal end, perpendicular to the sliding movement and against the bias of the spring 557.

[0127] like Fig.12 As shown, the barrier includes a latch seat 584 adapted to receive the wedge 556. Thus, as the attachment interface 550 slides further over the barrier interface 581 so that the tip of the wedge 556 passes through the leading edge 583, the bias of the compression spring 557 moves the wedge 556 so that it again protrudes from the attachment interface 550 and thereby extends into the latch seat 584. The wall of the latch seat 584 is adapted to push the attachment interface 550 further over the barrier interface 581 as the wedge 556 extends into the latch seat 584 due to the bias created by the spring 557. The attachment interface 550 can continue to slide over the barrier interface 581 in this manner until each of the plurality of sliders 404 touches a corresponding barrier slider (with respect to Fig.15 Refer to for further details).

[0128] As described above, movement of the actuator module 502 into engagement with the barrier 580, and specifically movement of the slider 404 into engagement with the barrier slider, can cause the ribs attached to the slider 404 to be stretched (via the rib receiving portion 20) until the tension in the ribs is balanced with the force introduced by the spring 557. The resulting tension in the ribs can increase the flexibility of the surgical instrument 500 (particularly the articulated modules, such as Fig.16 504) and reduce recoil in the surgical instrument 500 during use. The strength of the wedge 556 and spring 557 can be designed to achieve optimal tension in the tendon while preventing the risk of the wedge 556 being dislodged when external forces attempt to push the driver module 502 away from the barrier 580.

[0129] To disengage the driver module 502 from the barrier 580, the release handle 558 may be pulled away from the driver module 502, thereby causing the pair of latches 554 to move against the bias of their respective springs 557 and extract each wedge 556 from its respective latch seat 584. The driver module 502 may then be slid away from the barrier 580 in a direction opposite to the direction in which it was initially engaged.

[0130] Reference now Fig.13 According to another embodiment of the first aspect of the present invention, the driver module 602 is similar to Figure 10 to Figure 12 , except that the driver module includes a locking mechanism 652 that is different from the locking mechanism 552. First, the locking mechanism 652 includes a release bridge 658 instead of a release handle 558. Further, the locking mechanism 652 includes a movable pull ring 670 instead of a static handle 559. A bridge actuator 672 extends from the pull ring 670 under the release bridge 658 and into the outer housing (which is located in the embodiment of the present invention). Fig.13 The bridge actuator 672 is transparent in the figure), and the bridge brake expands in thickness as it extends away from the pull ring 670. The bridge actuator includes an inclined surface 674 that can engage with the release bridge 658 and can move the release bridge 658 relative to the rest of the driver module 602 based on the position of the bridge actuator 672. (Other features of the driver module 602, such as the plurality of sliders 404 and the shaft 503, are similar to Figure 10 to Figure 12 The driver module 502 shown is the same.)

[0131] In use, the release handle 558 is pulled to retract the latch 554 (eg, Fig.11 and 12 Instead, the user can pull the pull ring 670 away from the driver module 602 to move the bridge actuator 672 in the same direction as the pull ring 670. This can cause the inclined surface 674 to push against the release bridge 658 and further cause the release bridge 658 to slide over the bridge actuator 672, thereby raising the release bridge 658 away from the driver module 602. For example, when the release bridge 658 is raised, the latch 554 can be retracted into the driver module 602, and the driver module 602 can be aligned with the barrier (such as Fig.10 and 12 The barrier 580 shown in FIG. 5 is disengaged.

[0132] The pull ring 670 and bridge actuator 672 are movable parallel to the shaft 503 and the attachment interface 550. Thus, the user may advantageously be able to disengage the driver module 602 from the barrier 580 with a single motion in a single direction, rather than having to pull the release handle 558 in one direction while pulling the driver module 502 in a different direction.

[0133] Reference now Fig.14 , a barrier according to another embodiment of the second aspect of the present invention is generally defined by reference numeral 80. The barrier includes a first side 82 and a second side 83. The second side is configured to engage and cover a non-sterile item, such as a motor module. The first side is configured to engage with a non-sterile item, such as a motor module. Fig.10 The driver module 502 shown in FIG. 5 engages and protects the sterile items from the non-sterile items, thereby maintaining their sterility. Therefore, a barrier 80 is provided to form a physical barrier between the non-sterile items and the sterile items, such as the driver module according to the first aspect of the present invention, to ensure that the sterile items remain sterile.

[0134] Reference now Fig.15 , provides Fig.12 The barrier 80 further includes a plurality of barrier sliders 86, wherein each barrier slider of the plurality of barrier sliders 86 includes a first portion 88 and a second portion 89. Each first portion 88 can be engaged with a corresponding slider of the plurality of sliders 4, 104, 404, and the plurality of sliders can be respectively Figure 5 , 3 and the driver modules 302, 102, 502 shown in Figures 11. Each second portion 89 can be engaged with one of a plurality of actuators provided by the motor module.

[0135] Reference now Fig.16 A surgical instrument according to an embodiment of the second aspect of the present invention is generally indicated by reference numeral 700. The surgical instrument 700 includes Fig.10 and 13 The surgical instrument 700 further includes an articulation module 704 and an end effector 705. The articulation module 704 is coupled to the shaft 703, thereby positioning the shaft 703 between the driver module 702 and the articulation module 704. The end effector 705 is coupled to the articulation module 704, thereby positioning the articulation module 704 between the shaft 703 and the end effector 705.

[0136] Reference now Fig.17 A surgical instrument according to another embodiment of the second aspect of the present invention is generally indicated by reference numeral 800. The surgical instrument comprises Fig.10 and 15 The surgical instrument 800 further includes a pair of motor modules 807a, 807b and a barrier 880 that is similar to those shown in FIG. Fig.14 and 15, including a first side 882 and a second side 883. The pair of driver modules 802a, 802b are both engaged with the first side 882 of the barrier 880, and the pair of motor modules are both engaged with the second side 883 of the barrier 880.

[0137] Fig.17 Also shown is endoscope 808, which may be used with surgical instrument 800.

Claims

1. A driver module for actuating a tendon, the driver module comprising: a plurality of sliders, each of the plurality of sliders comprising a base portion, a rib receiving portion, and a body portion, the rib receiving portion being spaced apart from the base portion, and the body portion extending from the base portion to the rib receiving portion, The module further includes a slider receiving portion having a first end and a second end and engageable with the base portion of the slider such that the slider is movably attached to the slider receiving portion, The main body portion of each of the plurality of sliders further includes an alignment portion, wherein the alignment portion is adapted to place the rib receiving portions of adjacent sliders to abut or approach each other.

2. The driver module according to claim 1, characterized in that: It further includes a shaft receiving portion located toward the first end of the slider receiving portion, wherein the rib receiving portion is aligned with the shaft receiving portion.

3. The driver module according to claim 2, characterized in that: The alignment portion is adapted to position the rib receiving portion of the slider in alignment with a shaft aperture.

4. The driver module according to any one of claims 1 to 3, characterized in that: Each of the plurality of sliders further includes a drive portion extending from the base portion such that the base portion is positioned between the body portion and the drive portion.

5. The driver module according to any one of claims 1 to 3, characterized in that: The slider receiving portion includes a plurality of channels spaced apart from one another and extending at least partially along the length of the slider receiving portion between the first end and the second end, each of the plurality of channels being adapted to receive the base portion of one of the plurality of sliders such that the base portion is slidably movable within the channel.

6. The driver module according to any one of claims 1 to 3, characterized in that: It further includes a first roller having an axis and being configured to be axially rotatable, the first roller being positionable so that the axis of the first roller is perpendicular to the base portion of the slider and being engageable with the base portion of each of the plurality of sliders so that movement of the plurality of sliders causes the first roller to axially rotate.

7. The driver module according to claim 6, characterized in that: It further includes a second roller having an axis and configured to be axially rotatable, the first roller and the second roller being spaced apart from each other, the first roller being engageable with a first side of the base portion, and the second roller being engageable with a second side of the base portion.

8. The driver module according to any one of claims 1 to 3, characterized in that: It further includes a pretension actuator movable between a first position and a second position, wherein in the first position, the pretension actuator is engaged with the slider so that the slider is positioned toward the second end of the slider receiving portion, and in the second position, the pretension actuator is disengaged from the slider; The driver module further includes a biaser that biases the pretension actuator toward the first position.

9. The driver module according to claim 8, characterized in that: The driver module further includes a deactivation device engageable with the pretensioning actuator and movable to a deactivated position, wherein the pretensioning actuator is configured to be in its second position.

10. The driver module according to claim 1, characterized in that: The body portion of each slider includes a head portion positioned so that the head portion of the slider can abut the head portion of at least one other adjacent slider.

11. The driver module according to any one of claims 1 to 3, characterized in that: The driver module further includes an attachment interface engageable with the mating interface and a locking mechanism adapted to lock and unlock the engagement of the attachment interface with the mating interface.

12. The driver module according to claim 11, characterized in that: The locking mechanism includes a latch including a wedge, the latch being movable between a first position in which the wedge is received within the attachment interface and a second position in which the wedge protrudes from the attachment interface, wherein the latch is biased toward the second position.

13. The driver module according to any one of claims 1 to 3, characterized in that: The drive module further includes a gear assembly, which includes a gear slider capable of moving in a linear direction, a gear capable of rotating around a gear axis, and a geared shaft capable of rotating around a shaft axis; the gear slider can engage with the gear, and the gear can engage with the geared shaft, so that the linear movement of the linear slider drives the gear to rotate around the gear axis, thereby rotating the geared shaft around the shaft axis.

14. A surgical instrument comprising: A driver module according to any one of claims 1 to 13; a plurality of ribs, the plurality of ribs being receivable at a first end by the rib receiving portion of one of the plurality of sliders; an articulation module operably connectable to the rib; a shaft extending from the driver module to the hinge module, wherein the plurality of ribs extend through the shaft; an end effector operably connected to one or more of the plurality of ribs; as well as A motor module includes an actuator operatively engaged with the plurality of sliders such that movement of the actuator moves the plurality of sliders.

15. A surgical instrument comprising: The driver module according to any one of claims 1 to 13, comprising: a plurality of ribs, each of the ribs being retractably attached at a first end by the rib receiving portion of one of the plurality of sliders; a shaft extending from the driver module, the plurality of ribs extending through the shaft; an articulation module operatively coupled to the shaft and attachable at a second end thereof to one or more of the plurality of ribs; an end effector operatively coupled to the articulation module and attachable at a second end thereof to one or more of the plurality of tendons; and A motor module includes a plurality of actuators, each of the actuators being movable and engageable with the plurality of sliders such that movement of the actuator provides movement of a corresponding slider of the plurality of sliders.

16. The surgical instrument according to claim 15, characterized in that The surgical instrument further includes a barrier having a first side and a second side, the first side engageable with the driver module and the second side engageable with the motor module.

17. The surgical instrument according to claim 16, characterized in that The barrier includes a plurality of barrier sliders, each of the plurality of barrier sliders includes a first portion and a second portion, the first portion is engageable with one of the plurality of sliders of the driver module, and the second portion is engageable with one of the plurality of actuators of the motor module.

18. The surgical instrument according to claim 17, characterized in that: The driver module is a driver module according to claim 12, The mating interface is a barrier interface forming part of the first side of the barrier and includes a latch seat in which the wedge is receivable when the attachment interface is engaged with the barrier interface, and The wedge is adapted such that when the attachment interface is engaged with the barrier interface, the biasing of the latch toward the second position biases the driver module toward a position in which the plurality of sliders are engaged with the plurality of barrier sliders and the plurality of ribs are tensioned.

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