One-piece hinge link with on-axis bevel hinge cut-outs

Abstract

A medical device includes an articulated joint cut from a tubular member to include a plurality of links. Each of the links extends from a proximal end to a distal end and includes a channel extending therethrough. The proximal end of each of the plurality of links includes a proximal engagement feature, and the distal end of each of the plurality of links includes a distal engagement feature. The proximal engagement feature of one of the links is configured to movably engage the distal engagement feature of an adjacent one of the links to form a hinge via which adjacent links are movable relative to each other and the articulation joint is movable between a straight configuration and a curved configuration. The proximal engagement feature and the distal engagement feature include partial ramps corresponding to each other and extending therealong.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority to U.S. Provisional Application No. 63 / 484,840, filed on February 14, 2023, the entire contents of which are incorporated herein by reference. Background Art

[0003] Many endoscopic devices (e.g., endoscopes, ureteroscopes) and / or other medical devices are inserted through tortuous paths in a body cavity and may therefore include an articulating joint along the distal portion of its shaft (e.g., located at the distal portion of its shaft) to facilitate navigation of the endoscope or medical device through the body cavity. The articulating joint can be formed by a plurality of links movably connected to each other so that the distal portion of the shaft can be bent along it to deflect the distal end of the shaft relative to the longitudinal axis of the shaft. In some cases, the articulating joint may include 20 or more links to achieve the desired bending radius. Conventional articulating joints can be cut (e.g., laser cut) from a tubular body using, for example, a 5-axis laser cutting machine that uses a rotating laser and a mirror to cut each of the links. Angled cutting is achieved by using a mirror to reflect the laser beam. However, 5-axis laser cutting machines are expensive, have limited cutting angles, are generally not accurate enough to achieve the desired tolerances, and may have difficulty keeping all links of consistent size. Summary of the Invention

[0004] The present disclosure relates to a medical device comprising an articulated joint cut (e.g., laser cut) from a tubular member to include a plurality of links. Each of the links extends from a proximal end to a distal end and includes a channel extending therethrough. The proximal end of each of the plurality of links includes a proximal engagement feature, and the distal end of each of the plurality of links includes a distal engagement feature. The proximal engagement feature of one of the links is configured to movably engage the distal engagement feature of an adjacent one of the links to form a hinge via which the adjacent links can move relative to each other and the articulated joint can move between a straight configuration and a bent configuration. The proximal engagement feature and the distal engagement feature include partial ramps corresponding to and extending along each other.

[0005] In one embodiment, the proximal and distal engagement features include a pair of circular projections extending from diametrically opposed portions of a corresponding one of the proximal and distal edges of each of the plurality of links.

[0006] In one embodiment, the other of the proximal engagement feature and the distal engagement feature includes a pair of circular recesses sized and shaped to correspond to the circular protrusions so that the circular protrusions of adjacent links are rotatably received therein, the recesses extending through the wall of each of the plurality of links along a corresponding one of the proximal edge and the distal edge of each of the plurality of links.

[0007] In one embodiment, a portion of the edge intermediate the periphery of each of the lobe extends substantially perpendicular to the exterior surface of each link, and portions of the edge along opposing sides of each of the lobe include partial bevels.

[0008] In one embodiment, the midpoint of the edge defining each of the recesses is substantially perpendicular to the exterior surface of each link, and portions of the edge along opposing sides of each of the recesses are chamfered to correspond to the partial chamfers of the circular protrusions.

[0009] In one embodiment, the circular protrusion of a first one of the links is received within the recess of a second one of the links such that the circular protrusion is rotatable within the recess about an axis extending through a center point of the recess.

[0010] In one embodiment, the proximal edge of each of the links tapers toward the proximal engagement feature and the distal edge of each of the links tapers toward the distal engagement feature such that there is sufficient space between adjacent links for the adjacent links to rotate relative to each other.

[0011] In one embodiment, the articulated joint is symmetrical about a plane along which the articulated joint is configured to move between a straight configuration and a bent configuration.

[0012] The present disclosure also relates to a system for laser cutting an articulated joint. The system includes a non-transitory computer-readable storage medium storing an executable program and a processor executing the executable program to cause the processor to perform the following operations: controlling a laser so that the laser is movable along three axes and rotating a tubular member about a longitudinal axis corresponding to one of the three axes, such that an articulated joint is cut from the tubular member via the laser, the articulated joint comprising a plurality of links, each of the links extending from a proximal end to a distal end, the proximal end of each of the plurality of links comprising a proximal engagement feature, and the distal end of each of the plurality of links comprising a distal engagement feature, the proximal engagement feature of one of the links being configured to movably engage the distal engagement feature of an adjacent one of the links to form a hinge, via which the adjacent links are rotatable relative to each other and the articulated joint is movable between a straight configuration and a bent configuration, and laser cutting the tubular member such that the proximal engagement feature and the distal engagement feature include partial ramps corresponding to and extending along each other to prevent separation of the adjacent links.

[0013] In one embodiment, the processor controls the laser to cut the tubular member to define hinges between adjacent links, one of the proximal engagement feature and the distal engagement feature includes a pair of circular protrusions extending from radially opposing portions of a corresponding one of the proximal and distal edges of each of the plurality of links, and the other of the proximal and distal engagement features includes a pair of correspondingly sized and shaped circular recesses extending through a wall of each of the plurality of links along a corresponding one of the proximal and distal edges of each of the plurality of links.

[0014] In one embodiment, the processor controls the laser to cut the hinge such that a circular protrusion of a first one of the links is configured to rotate within a corresponding recess of an adjacent second one of the links about an axis extending through a center point of the recess.

[0015] In one embodiment, the processor controls the laser to extend perpendicularly relative to the longitudinal axis along a portion of the tubular member to form corresponding straight edges along a portion of the circular projection and a portion of the recess.

[0016] In one embodiment, the processor controls the laser to cut corresponding bevels along opposing sides of the recess and lobe, the angles of the bevels being determined via the distance of the laser from the longitudinal axis of the tubular member and the rotation of the tubular member.

[0017] In one embodiment, the processor controls the laser to cut away portions of the tubular member to define proximal and distal edges of each of the links, the proximal edge of each of the links tapering toward the proximal engagement feature and the distal edge of each of the links tapering toward the distal engagement feature such that sufficient space exists between adjacent links for the adjacent links to rotate relative to each other.

[0018] In one embodiment, the processor controls the laser to cut the tubular member such that the articulating joint is symmetrical about a plane along which the articulating joint is configured to move between a straight configuration and a bent configuration.

[0019] In addition, the present disclosure relates to a method for manufacturing an articulated joint for a medical device. The method includes using a four-axis laser cutting machine to laser cut a tubular member to form an articulated joint including a plurality of links. The four-axis laser cutting machine includes a laser that can move along three axes and a tubular member that can rotate about its longitudinal axis. Each of the links extends from a proximal end to a distal end. The proximal end of each of the plurality of links includes a proximal engagement feature, and the distal end of each of the plurality of links includes a distal engagement feature. The proximal engagement feature of one of the links is configured to movably engage the distal engagement feature of an adjacent one of the links to form a hinge, via which the adjacent links can rotate relative to each other and the articulated joint can move between a straight configuration and a bent configuration. The proximal engagement feature and the distal engagement feature include partial slopes corresponding to and extending along each other to prevent the adjacent links from separating from each other.

[0020] In one embodiment, the tubular member is laser cut to define hinges between adjacent links, one of the proximal engagement feature and the distal engagement feature comprises a pair of circular protrusions extending from radially opposing portions of a corresponding one of the proximal and distal edges of each of the plurality of links, and the other of the proximal and distal engagement features comprises a pair of correspondingly sized and shaped circular recesses extending through a wall of each of the plurality of links along a corresponding one of the proximal and distal edges of each of the plurality of links.

[0021] In one embodiment, the laser extends perpendicularly relative to the longitudinal axis along a portion of the tubular member to cut straight edges along corresponding portions of the proximal and distal engagement features.

[0022] In one embodiment, the laser cuts bevels along opposing sides of the recess and lobe, the angle of the bevel being determined via the distance of the laser from the longitudinal axis of the tubular member and the rotation of the tubular member.

[0023] In one embodiment, a portion of the tubular member is laser cut to define a proximal edge and a distal edge of each of the links, such that the proximal edge of each of the links tapers toward the proximal engagement feature and the distal edge of each of the links tapers toward the distal engagement feature such that sufficient space exists between adjacent links for the adjacent links to rotate relative to each other. BRIEF DESCRIPTION OF THE DRAWINGS

[0024] Figure 1 shows a longitudinal side view of an articulated joint cut from a single tubular member according to an exemplary embodiment of the present disclosure;

[0025] Figure 2 Shown according to Figure 1 an enlarged longitudinal side view of adjacent links of an articulated member connected to each other via a hinge;

[0026] Figure 3 Shown Figure 1 A longitudinal side view of the articulated joint in a bent configuration;

[0027] Figure 4 Shown according to Figure 1 A perspective cross-sectional view of a portion of the articulated joint along line CC;

[0028] Figure 5 Shown according to Figure 1 A cross-sectional plan view of the articulated joint along line CC;

[0029] Figure 6 Shown according to Figure 1 an enlarged longitudinal side view of a hinge between adjacent links of an articulated joint;

[0030] Figure 7 Shown in accordance with Figure 6 an enlarged view of a cutout formed between mating portions of a hinge between adjacent links of an articulated joint;

[0031] Figure 8 Shown according to Figure 7 A cross-sectional side view of the hinge along line AA; and

[0032] Figure 9 Shown according to Figure 1 A schematic diagram of an exemplary embodiment of a laser cutting system for laser cutting a tubular member. DETAILED DESCRIPTION

[0033] The present disclosure may be further understood with reference to the following description and accompanying drawings, in which like elements are represented by like reference numerals. The present disclosure relates to a medical device, and in particular to a medical device comprising an articulating joint. Exemplary embodiments of the present disclosure describe an articulating joint that is configured to extend along a distal portion of a shaft of, for example, a medical device such as an endoscope or ureteroscope. An exemplary articulating joint may be formed from a single tubular member that is cut (e.g., laser cut) to form a plurality of links, each of which is connected to one or two adjacent links via corresponding mating features that engage each other to form a hinge that allows the adjacent links to rotate relative to each other.

[0034] According to an exemplary embodiment, the tubular member can be cut via a 4-axis laser cutter (i.e., a device including a laser that can move along three axes (e.g., an X-axis, a Y-axis, and a Z-axis)) while the tubular member is rotated about its longitudinal axis. The laser cutter laser cuts the tubular member to define each of the links and, in particular, cuts a portion of the hinge to include a partial bevel that prevents adjacent links from separating from each other. Although the exemplary embodiment describes the articulating joint as being configured for use with endoscopic devices including, for example, endoscopes and ureteroscopes, those skilled in the art will understand that the articulating joint can be used in any of a variety of medical devices in which bending along any portion of its axis is desired. Those skilled in the art will also understand that, as used herein, the terms "proximal" and "distal" are intended to refer to directions toward (proximal) and away from (distal) a user of the device (e.g., a physician).

[0035] like Figures 1-8 As shown in , an articulating joint 100 according to an exemplary embodiment of the present disclosure includes a plurality of links 102 that are movably connected to each other to facilitate bending of the articulating joint 100 within a plane that includes the longitudinal axis L of the articulating joint 100. As will be understood by those skilled in the articulating joint 100, as used herein, the term "axis" describes a path along the center of the articulating joint 100 from the proximal end of the articulating joint 100 to its distal end. The axis can be curved or straight, depending on the arrangement of the articulating joint 100 at a given time, and within certain tolerances, the axis can deviate from a plane. However, the articulating joint 100 of this embodiment is formed so that bending of the articulating joint 100 along the axis is substantially within a single plane.

[0036] like Figure 1As shown in FIG, an articulating joint 100 of this embodiment is cut from a single tubular member 101, the articulating joint extending along a longitudinal axis L from a proximal end 150 to a distal end 152, and is configured to form, for example, a distal portion of a shaft of a medical device (e.g., an endoscope, a ureteroscope) to enhance bending of the shaft in this portion so that a user (e.g., a physician) can manipulate the distal end of the shaft to navigate the shaft through a tortuous path of a body lumen. As will be understood by those skilled in the articulating joint, an articulating joint according to another embodiment can be constructed in the same manner as articulating joint 100, except that the proximal and distal ends of the another embodiment are reversed compared to articulating joint 100. That is, the joint of the another embodiment can be constructed in the same manner as articulating joint 100, except that the proximal end of the another embodiment will be located at the end of articulating joint 100 indicated by 152, while the distal end of the joint of the another embodiment will be located at the end indicated by 150.

[0037] Each of the links 102 of the articulating joint 100 includes a proximal engagement feature 104 located at a proximal end 108 of the link and a distal engagement feature 106 located at a distal end 110 of the link. Each of the proximal engagement features 104 corresponds in size and shape to the distal engagement feature 106 with which it is engaged, such that the proximal engagement feature 104 of a first link 102a engages the distal engagement feature 106 of a second link 102b adjacent to the first link 102a to form a hinge 112 therebetween. The hinge 112 is configured to permit adjacent links 102a, 102b to move (e.g., rotate) relative to each other. The hinge 112 facilitates rotation of each of the adjacent links 102a, 102b relative to each other, such that the articulating joint 100 can be moved to a position such as Figure 1 The substantially straight configuration shown in Figure 3 As will be described in further detail below, to prevent adjacent links 102a, 102b from separating from one another at hinge 112, angled cutouts 114 are formed in the tubular member 101 of this embodiment to define proximal and distal engagement features 104, 106 of adjacent links 102a, 102b, each having corresponding partial ramps 128, 138, respectively.

[0038] As described above, the articulated joint 100 includes links 102, each of which (e.g. Figure 2 and Figure 4102 extends from a proximal end 108 to a distal end 110 and includes a channel 116 extending therethrough. The proximal engagement feature 104 of each of the links 102 defines a proximal edge 120 that forms a proximally facing end surface of each of the links 102. In the exemplary embodiment, the proximal engagement feature is configured as a pair of circular protrusions 118 that extend proximally from the proximal edge 120 along radially opposing portions of the link 102. In particular, the proximal edge 120 extends between and connects a radially outer surface 134 (i.e., the surface farthest from and facing away from the axis L) and an inner surface 136 (facing the axis L) of the link 102. In the exemplary embodiment, each of the circular protrusions 118 is substantially circular. The portions of the proximal edge 120 located on either side of each of the circular protrusions 118 are angled to taper toward a distal end 122 of each of the circular protrusions 118 until one of the tapered edges extending away from a first of the circular protrusions 118 intersects a corresponding one of the edges extending away from a second of the circular protrusions 118.

[0039] Similarly, the distal end 110 of each of the links 102 includes a distal engagement feature 106 that forms a distal edge 126 of each of the links 102. In this embodiment, each of the distal engagement features 106 includes a pair of diametrically opposed recesses 124 that extend from an exterior surface 134 through a wall 146 of one of the links 102 (e.g., the second link 102b) to an interior surface 136. Each of the recesses 124 of the second link 102b is configured (sized, shaped, and positioned) to rotatably receive a corresponding one of the circular protrusions 118 of the immediately adjacent, more distal first link 102a. The distal edge 126 of the second link 102b extends between the exterior surface 134 and the interior surface 136 of the second link 102b to connect the exterior surface 134 and the interior surface 136 at the distal end 110 of the second link 102b.

[0040] As described above, the recesses 124 of the second link 102b are sized and shaped to correspond to the circular protrusions 118 of the first link 102a and extend from the distal edge 126 through a diametrically opposed portion of the second link 102b, longitudinally aligned with the circular protrusions 118 of the first link 102a. In an exemplary embodiment, each of the recesses 124 of the second link 102b is substantially circular to match the circular shape of the circular protrusions 118 of the first link 102a, such that these circular protrusions 118 and corresponding recesses 124 act as hinges 112 between the first link 102a and the second link 102b. The hinges 112 permit the adjacent first and second links 102a, 102b to rotate relative to each other about an axis extending through, for example, a center point of each of the recesses 124. The distal edge 126 is also angled to taper toward the distal end 110 so that the angles of the proximal and distal edges 120, 126 provide sufficient clearance between adjacent links 102a, 102b as they rotate relative to one another. Those skilled in the art will appreciate that this same relationship between the recess 124 of any one of the links 102 and the immediately distal circular protrusion 118 of the second link 102b will be similar, provided that the size, shape, and position of the recess 124 and circular protrusion 118 of each pair of adjacent links 102 are selected to permit maintenance of the mechanical engagement of the coupling between the links 102 while permitting rotation relative to one another within the permissible range of rotation.

[0041] As will be described in further detail below, according to an exemplary embodiment, articulated joint 100 is cut from a single tubular member 101 formed of, for example, metal. Tubular member 101 can be cut using, for example, a laser cutter to define each of individual links 102. To prevent adjacent links 102 from separating from each other, a portion of each hinge 112 of this embodiment is cut at an angle such that each of circular protrusion 118 and recess 124 includes partial bevels 128, 138, respectively, that correspond to one another to permit engagement therebetween.

[0042] In an exemplary embodiment, the proximal-most point 132 of each of the circular protrusions 118 includes a straight edge. In other words, the edge 130 of each of the circular protrusions 118 extends substantially perpendicular to the inner surface 136 and the outer surface 134 of the circular protrusion 118 (e.g., perpendicular to the outer surface 134 and / or the inner surface 136 of the link 102 of the tubular member 101) at the protrusion's proximal-most point 132 (e.g., a midpoint along the periphery of the circular protrusion 118). However, the bevel 128 extends along the portion of the edge 130 of each of the circular protrusions 118 that extends between the protrusion's proximal-most point 132 and the distal end 122, along the opposite side of the circular protrusion 118, as shown. Figure 4 and Figure 5 The ramp 128 extends at a non-perpendicular angle relative to the exterior surface 134 and the interior surface 136 of each of the links 102 .

[0043] In an exemplary embodiment, the portions of the bevel 128 along opposite sides of each of the lobe 118 are symmetrical relative to each other (relative to the midpoint 132). The angle of the bevel 128 may also vary along the lobe from its proximal-most point 132 to the distal end 122. In an exemplary embodiment, the angle of the bevel 128 may be greatest at a mid-portion between the proximal-most point 132 and the distal end 122 of the lobe 118. Those skilled in the art will appreciate that the cross-sectional area of ​​the interior surface 136 along each of the lobe 118 will be smaller than the cross-sectional area of ​​the exterior surface 134 along each of the lobe 118.

[0044] The partial ramp 138 of each of the recesses 124 corresponds to the partial ramp 128 of the link 102, so that the circular protrusion 118 and the recess 124 or the adjacent links 102a, 102b can be movably engaged with each other. In particular, the partial ramp 138 of each of the recesses 124 is configured to mate with the circular protrusion 118 and the recess 124 of the proximal engagement feature 104 and the distal engagement feature 106, while allowing each circular protrusion 118 to rotate within a predetermined angular range within the corresponding recess 124.

[0045] According to one exemplary embodiment, portions of the ramps 128, 138 may extend at an angle of less than 10 degrees relative to an axis extending perpendicular to the exterior surface 134. In another exemplary embodiment, portions of the ramps 128, 138 may extend at an angle ranging, for example, between 6 and 9 degrees. However, those skilled in the art will appreciate that the ramps 128, 138 may have any of a variety of angles relative to an axis perpendicular to the exterior surface 134 of the articulation joint 100, so long as the angles of the ramps 128, 138 of the diametrically opposed circular protrusions 118 and recesses 124 prevent disengagement of adjacent links 102 of the articulation joint 100.

[0046] According to an exemplary embodiment, the proximal-most point 142 (e.g., the midpoint) of each of the recesses includes a straight edge. Specifically, a portion of the surface or edge 140 defining each recess 124 extends perpendicularly relative to the exterior surface 134 and the interior surface 136 of the link 102, while a bevel 138 extends along the opposite side of the recess 124 between the proximal-most point 142 and the distal edge 126 of the link 102, as shown. Figure 4 and Figure 5Because the proximal engagement feature 104 and the distal engagement feature 106 are configured to mate with one another, similar to the ramp 128 of the circular protrusion 118, in this embodiment, the portions of the ramp 138 extending along opposite sides of each of the recesses 124 are symmetrical to one another (relative to the midpoint).

[0047] Additionally, similar to bevel 128, the angle of bevel 138 corresponds thereto, and the angle of bevel 138 may vary along bevel 138 from its proximal-most point 142 to the distal end of distal edge 126. In an exemplary embodiment, the angle of bevel 138 is greatest midway between the proximal-most point 142 of recess 124 and the distal end of distal edge 126.

[0048] In the exemplary embodiment, the links 102 of articulated joint 100 (including the angles of the inclined surfaces) are also symmetrical about the plane in which the links 102 can rotate relative to each other. In other words, each of the circular protrusions 118 is symmetrical about the plane in which the corresponding recess 124 of the link (with which the circular protrusion forms a hinge). Therefore, the partial inclined surfaces 128, 138 extending along opposite sides of the circular protrusion 118 and recess 124, respectively, are sufficient to prevent adjacent links in the links 102 from separating from each other while permitting relative movement (i.e., rotation) therebetween.

[0049] As will be appreciated by those skilled in the art, each of the links 102 can also be configured to include a plurality of slots 144 extending from the exterior surface 134 through a wall 146 of the link to the exterior surface 136, wherein the slots 144 are configured to receive wires, cables, or other control elements therethrough. In an exemplary embodiment, the slots 144 of each of the links 102 extend through a portion of the wall 146 that extends between radially opposing distal engagement features 106 (and proximal engagement features 104) of the link 102. For example, in one embodiment, the slots 144 are offset 90 degrees from the proximal and distal engagement features 104, 106 of the link 102 about the longitudinal axis L. According to an exemplary embodiment, a portion of the wall extending between adjacent slots 144 along the longitudinal axis L is radially inwardly curled, such that a control element can pass through the inwardly curled portion of each of the links 102 to facilitate bending and / or deflection of the articulation joint 100, as will be appreciated by those skilled in the articulation joint 100.

[0050] Those skilled in the art will also understand that the most proximal of the links 102 will include only the distal engagement feature 106, while the most distal of the links 102 will include only the proximal engagement feature 104. Additionally, while the exemplary embodiment shows and describes the circular protrusion 118 as the proximal engagement feature 104 and the recess 124 as the distal engagement feature 106, those skilled in the articulation joint 100 will understand that the exemplary articulation joint 100 can be oriented in either direction relative to the axis of the medical device. In other words, in another embodiment, the circular protrusion 118 can extend from the distal end 110, while the recess 124 of corresponding size and shape can be formed at the proximal end 108 of each of the links 102.

[0051] According to an exemplary system and method for manufacturing an articulating joint 100, links 102 of the articulating joint can be cut from a single tubular member 101 using a 4-axis laser cutting system 10 that includes a laser 12 controlled via a processor 14 to move the laser 12 along three axes while the tubular member 101 rotates about its longitudinal axis L (i.e., a fourth axis of motion). The laser cutting system 10 can include, for example, a picosecond laser or a femtosecond laser, wherein the laser 12 extends along one of the three axes (X, Y, Z), such as Figure 9 As shown, the laser can be moved along the axes relative to the tubular member 101. According to an exemplary embodiment, the X-axis corresponds to the offset or distance of the laser 12 from the longitudinal axis L of the tubular member 101, the Y-axis corresponds to the distance of the laser 12 from the tubular member 101, and the Z-axis corresponds to the longitudinal axis L of the tubular member 101, about which the tubular member 101 can rotate.

[0052] The processor 14 of one embodiment includes and / or is connected to a memory 16 that is configured to include instructions for laser cutting the tubular member 101, as will be described in further detail below. For example, the memory 16 can be a non-transitory computer-readable storage medium that includes instructions that can be executed via the processor 14. The processor 14 can be configured to execute computer-executable instructions from the operation of applications stored in the memory 16 to provide functionality to the laser cutting system 10. Those skilled in the art will understand that although the laser cutting system 10 is shown as including a single processor 14 and a separate memory 16, the functionality described with respect to the laser 12 can be implemented via modular components connected to the processor 14 or via more than one processor 14. For example, the laser cutting system 10 can be composed of a network of computing systems, each of which includes one or more of the above-described components.

[0053] As described above, in the exemplary manufacturing method, the tubular member 101 is laser cut by moving the laser 12 along the X-axis, the Y-axis, and the Z-axis while rotating the tubular member 101 about the longitudinal axis L (e.g., the Z-axis) to define each of the links 102. Specifically, portions of the tubular member 101 are cut away to define the proximal edge 120 and the distal edge 126 of each of the links 102. Although the proximal-most ends 132, 142 of the circular protrusion 118 and the recess 124, respectively, are cut when the laser 12 is positioned substantially perpendicular to the exterior surface 134 and aligned with the longitudinal axis L, the partial bevels 128, 138 of the circular protrusion 118 and the recess 124, respectively, are formed via the laser cut 114 extending through the wall 146 of the tubular member 101 at an angle relative to the axis that is perpendicular to the exterior surface 134 at that point.

[0054] like Figure 6-Figure 8 , laser cuts 114 along opposite sides 148 of hinge 112 (e.g., the portion of laser cut 114 extending between distal end 122 and proximal-most point 132 of lobe 118) are achieved by moving laser 12 along the X-axis while also rotating tubular member 101 about longitudinal axis L and moving laser 12 along the Z-axis. In particular, the angles of laser cuts 114 along opposite sides 148 of hinge 112 will be determined via the offset of laser 12 relative to longitudinal axis L and the rotation of tubular member 101 about longitudinal axis L.

[0055] Those skilled in the art will appreciate that the axis B along which the laser cut 114 extends through the tubular member 101 to define the beveled surfaces 128, 138 will have a maximum angle relative to the axis P, being perpendicular to the exterior surface 134 and the interior surface 136 at that point (at the radially outermost points of the circular protrusion 118 and the recess 124). As discussed above, in one embodiment, the axis B along which the laser cut 114 is formed may extend at an angle of less than 10 degrees relative to the axis P, and in another more specific embodiment, may extend at an angle ranging between 6 and 9 degrees. However, those skilled in the art will appreciate that the angle of the axis B relative to the axis P may vary as desired, so long as the portions of the beveled surfaces 128, 138 defined via the laser cut 114 prevent adjacent links 102 of the articulated joint 100 from disengaging and / or separating from one another, while also permitting rotation of the adjacent links 102 relative to one another, as described above.

[0056] The laser cuts 114 are angled along opposite sides 148 of the hinge 112 so that when viewed from one side of the hinge joint, as shown in FIG. Figure 7-Figure 8, the points where the ramps 128, 138 intersect the interior surfaces 136 of the links 102 are not visible from the exterior of the articulation joint 100. As described above, the tubular member 101 is cut symmetrically about the longitudinal axis L (specifically, about the plane along which adjacent links 102a, 102b can rotate) such that the partial ramps 128, 138 of the proximal and distal engagement features 104, 106, respectively, prevent the adjacent links 102a, 102b from separating from one another while also permitting the circular protrusion 118 of each of the links 102 to rotate within the corresponding recess 124 of an adjacent one of the links 102.

[0057] Those skilled in the art will appreciate that changes may be made to the above-described embodiments without departing from the concept of the present invention. It should be further understood that the structural features and methods associated with one embodiment may be incorporated into other embodiments. Therefore, it should be understood that the present invention is not limited to the specific embodiments disclosed, and modifications are encompassed within the scope of the present invention as defined by the appended claims.

Claims

1. A medical device comprising: An articulating joint is cut from a tubular member to include a plurality of links, each of the links extending from a proximal end to a distal end and including a channel extending therethrough, the proximal end of each of the plurality of links including a proximal engagement feature, and the distal end of each of the plurality of links including a distal engagement feature, the proximal engagement feature of one of the links being configured to movably engage the distal engagement feature of an adjacent one of the links to form a hinge, via which the adjacent links are movable relative to each other, and the articulating joint being movable between a straight configuration and a bent configuration, the proximal engagement feature and the distal engagement feature including partial ramps corresponding to and extending along each other.

2. The device according to claim 1, wherein One of the proximal and distal engagement features includes a pair of circular projections extending from radially opposing portions of a corresponding one of the proximal and distal edges of each of the plurality of links.

3. The device according to claim 2, wherein The other of the proximal and distal engagement features includes a pair of circular recesses sized and shaped to correspond to the circular protrusions so that the circular protrusions of adjacent links are rotatably received therein, the recesses extending through a wall of each of the plurality of links along a corresponding one of the proximal and distal edges of each of the plurality of links.

4. The device according to claim 2, wherein A portion of the edge intermediate the periphery of each of the circular projections extends substantially perpendicular to the exterior surface of each link, and portions of the edge along opposing sides of each of the circular projections include partial bevels.

5. The device according to claim 3, wherein A midpoint of an edge defining each of the recesses is substantially perpendicular to an exterior surface of each link, and portions of the edge along opposite sides of each of the recesses are chamfered to correspond to partial chamfers of the circular protrusions.

6. The device according to claim 3, wherein The circular protrusion of a first one of the links is received within the recess of a second one of the links such that the circular protrusion is rotatable within the recess about an axis extending through a center point of the recess.

7. The device according to claim 2, wherein The proximal edge of each of the links tapers toward the proximal engagement feature, and the distal edge of each of the links tapers toward the distal engagement feature such that there is sufficient space between adjacent links for the adjacent links to rotate relative to each other.

8. The device according to any one of claims 1 to 7, wherein: The articulated joint is symmetrical about a plane, and the articulated joint is configured to move along the plane between the straight configuration and the bent configuration.

9. A system for laser cutting an articulated joint, the system comprising: a non-transitory computer-readable storage medium storing an executable program; and a processor that executes the executable program so that the processor: The laser is controlled to move along three axes and to rotate a tubular member about a longitudinal axis corresponding to one of the three axes, so that the articulated joint is cut from the tubular member via the laser, the articulated joint comprising a plurality of links, each of the links extending from a proximal end to a distal end, the proximal end of each of the plurality of links comprising a proximal engagement feature, and the distal end of each of the plurality of links comprising a distal engagement feature, the proximal engagement feature of one of the links being configured to movably engage the distal engagement feature of an adjacent one of the links to form a hinge, via which adjacent links are rotatable relative to each other, and the articulated joint is movable between a straight configuration and a bent configuration, the tubular member being cut by the laser so that the proximal engagement feature and the distal engagement feature comprise partial ramps corresponding to and extending along each other to prevent adjacent links from separating from each other.

10. The system according to claim 9, wherein: The processor controls the laser to cut the tubular member to define the hinge between adjacent links, one of the proximal and distal engagement features comprising a pair of circular protrusions extending from radially opposing portions of a corresponding one of the proximal and distal edges of each of the plurality of links, and the other of the proximal and distal engagement features comprising a pair of correspondingly sized and shaped circular recesses extending through a wall of each of the plurality of links along a corresponding one of the proximal and distal edges of each of the plurality of links.

11. The system according to claim 10, wherein: The processor controls the laser to cut the hinge such that the circular protrusion of a first one of the links is configured to rotate within a corresponding recess of an adjacent second one of the links about an axis extending through a center point of the recess.

12. The system according to claim 10, wherein: The processor controls the laser to extend perpendicularly relative to the longitudinal axis along a portion of the tubular member to form corresponding straight edges along a portion of the circular protrusion and a portion of the recess.

13. The system according to claim 11, wherein: The processor controls the laser to cut corresponding bevels along opposing sides of the recess and the lobe, the angles of the bevels being determined via the distance of the laser from the longitudinal axis of the tubular member and the rotation of the tubular member.

14. The system according to claim 10, wherein: The processor controls the laser to cut away portions of the tubular member to define proximal and distal edges of each of the links, the proximal edge of each of the links tapering toward the proximal engagement feature and the distal edge of each of the links tapering toward the distal engagement feature such that sufficient space exists between adjacent links for the adjacent links to rotate relative to each other.

15. The system according to any one of claims 9 to 14, wherein: The processor controls the laser to cut the tubular member such that the articulating joint is symmetrical about a plane, the articulating joint being configured to move between the straight configuration and the bent configuration along the plane.

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