Surgical tool end effector with replaceable blade

Abstract

A method of replacing a blade of an end effector of a surgical tool includes moving the end effector distally from an assembled condition in which the end effector is rotatably mounted to a clevis to an extended condition in which a shaft is moved out of a slot of an end opening defined in opposing arms of the clevis. The end effector includes opposing first and second blades mounted to first and second blade holders, the first and second blade holders being rotatably mounted to the shaft. The blade holder can be detached from the blade in opposite lateral directions, and a new blade set including a new blade and a new shaft can then be mounted to the holder, and the end effector moves proximally and returns to the assembled state by receiving the new shaft within the slot of the end opening.

Description

Background Technology

[0001] Minimally invasive surgical (MIS) instruments are generally superior to traditional open surgical devices due to reduced postoperative recovery time and minimized scarring. Laparoscopic surgery is a type of MIS procedure in which one or more small incisions are made in the patient's abdomen, and a cannula is inserted through these incisions to create access to the abdominal cavity. A variety of instruments and surgical tools can be introduced into the abdominal cavity via the cannula. These instruments and tools introduced into the abdominal cavity via the cannula can be used to engage and / or manipulate tissue in a variety of ways to achieve diagnostic or therapeutic effects.

[0002] Various robotic systems have been developed to assist in MIS surgery. These systems enable more instinctive hand movements by maintaining a natural hand-eye axis. They also allow for greater degrees of freedom of movement through a "wrist" joint capable of jointing, enabling more natural hand-like joint movements. In such systems, an end effector positioned at the distal end of the instrument can perform joint movements (mobility) using a cable-driven motion system with one or more drive cables extending through the wrist joint. A user (e.g., a surgeon) can remotely operate the end effector by grasping and manipulating one or more controllers in space, which are connected to a tool actuator coupled to the surgical instrument. User input is processed by a computer system integrated into the robotic surgical system, and the tool actuator responds by actuating the cable-driven motion system. Motion of the drive cables moves the end effector joint to the desired angular position and configuration.

[0003] Some end effectors include high-wear components that can mechanically or physically degrade over time, thereby limiting the lifespan of the end effector. An example of a high-wear component is the blade of surgical scissors, which can become dull over time, thus adversely affecting the efficiency of the end effector. What is needed is a method and system for more easily replacing the blades of end effectors, providing users (e.g., surgeons, nurses, etc.) with a fresh set of blades for each new use of the surgical instrument. Attached Figure Description

[0004] The following figures are included to illustrate certain aspects of this disclosure and should not be considered as exclusive embodiments. The subject matter disclosed herein can have numerous modifications, alterations, combinations, and equivalents in form and function without departing from the scope of this disclosure.

[0005] Figure 1 This is a block diagram of an example robotic surgical system that can incorporate some or all of the principles of this disclosure.

[0006] Figure 2It is an isometric side view of an example surgical tool that can be incorporated into some or all of the principles of this disclosure.

[0007] Figure 3 It shows that Figure 2 The wrist of a surgical instrument has the potential degrees of freedom for joint movement (pivot) and translation.

[0008] Figure 4 yes Figure 2 An enlarged isometric view of the distal end of a surgical instrument.

[0009] Figure 5A and Figure 5B These are based on one or more implementation schemes. Figure 4 Enlarged left and right isometric views of the end effector.

[0010] Figure 6A and Figure 6B These are based on one or more implementation schemes. Figure 4 The left and right isometric views of the decomposed end effector.

[0011] Figure 7A and Figure 7B These are based on one or more implementation schemes. Figure 4 Enlarged, exploded left and right isometric views of the end effector.

[0012] Figures 8 to 11 The progressive steps for disassembling the end effector according to an embodiment of the present disclosure are described.

[0013] Figure 12 It is an enlarged isometric view of a reassembled new blade assembly according to one or more embodiments of this disclosure.

[0014] Figure 13A and Figure 13B These are enlarged isometric views and exploded views of an end effector according to one or more additional embodiments of this disclosure.

[0015] Figure 14A and Figure 14B These are enlarged isometric views and exploded views of an end effector according to one or more additional embodiments of this disclosure. Detailed Implementation

[0016] This disclosure relates to robotic surgical systems, and more specifically to methods and systems for changing the blades of end effector surgical scissors.

[0017] The method and system discussed herein for replacing end effector blades include moving the end effector from an assembled state to an extended state, in which the end effector is rotatably mounted to a connecting fork, and in the extended state, removing the shaft from an open-ended slot defined in an end opening in an opposing arm of the connecting fork. The end effector includes opposing first and second blades mounted to a first and a second blade holder, which are rotatably mounted to the shaft. The blade holders can be separated from the blades in opposite lateral directions, and a new blade assembly including the new blade and the new shaft can then be mounted to the holders, and the end effector moves proximally and returns to the assembled state by receiving the new shaft within the slot of the end opening.

[0018] Figure 1 This is a block diagram of an example robotic surgical system 100 that incorporates some or all of the principles of this disclosure. As shown, system 100 may include at least one set of user input controllers 102a and at least one control computer 104. Control computer 104 may be mechanically and / or electrically coupled to a robotic manipulator, and more specifically to one or more robotic arms 106 (alternatively referred to as “tool drivers”). In some embodiments, the robotic manipulator may be included in or otherwise mounted to an arm carriage that enables system portability. Each robotic arm 106 may include and otherwise provide a location for mounting one or more surgical instruments or tools 108 to perform various surgical tasks on patient 110. Operation of the robotic arms 106 and associated tools 108 may be guided by a clinician 112a (e.g., a surgeon) from user input controllers 102a.

[0019] In some embodiments, a second clinician 112b may operate a second set of user input controllers 102b (shown in dashed lines) to guide the operation of the robotic arm 106 and tool 108 via a control computer 104, together with the first clinician 112a. In such embodiments, for example, each clinician 112a, 112b may control a different robotic arm 106, or in some cases, full control of the robotic arm 106 may be transferred between clinicians 112a, 112b as needed. In some embodiments, additional robotic manipulators with additional robotic arms may be used on the patient 110 during surgery, and these additional robotic arms may be controlled by one or more of the user input controllers 102a, 102b.

[0020] The control computer 104 and user input controllers 102a and 102b can communicate with each other via a communication link 114, which can be any type of wired or wireless communication component configured to carry various communication signals (e.g., electrical signals, optical signals, infrared signals, etc.) according to any communication protocol. In some applications, for example, there is a tower with auxiliary equipment and a processing core designed to drive the robotic arm 106.

[0021] User input controllers 102a, 102b typically include one or more physical controllers that can be grasped by clinicians 112a, 112b and manipulated in space by surgeons while observing surgery via a stereoscopic display. The physical controllers typically include manual input devices capable of movement in multiple degrees of freedom and typically include actuable handles for actuating surgical instruments 108, such as for opening and closing opposing jaws, applying a potential (current) to electrodes, etc. Control computer 104 may also include optional feedback meters that can be viewed by clinicians 112a, 112b via a display to provide visual indications of various surgical instrument measurements, such as the magnitude of the force applied to the surgical instruments (i.e., cutting instruments or dynamic clamping members).

[0022] Figure 2 This is an isometric side view of an example surgical tool 200 that can be incorporated into some or all of the principles of this disclosure. The surgical tool 200 can be used with... Figure 1 The surgical tools 108 are the same as or similar to those used in robotic surgical systems (such as...). Figure 1 The surgical tool 200 is used in conjunction with the robotic surgical system 100. Therefore, the surgical tool 200 can be designed to be releasably coupled to a tool actuator included in the robotic surgical system 100. However, in other embodiments, aspects of the surgical tool 200 may be adapted for manual or hand-operated use without departing from the scope of this disclosure.

[0023] As shown in the figure, the surgical tool 200 includes an elongated shaft 202, an end effector 204, a wrist 206 (alternatively referred to as a "wrist joint" or "wrist joint capable of joint movement") connecting the end effector 204 to the distal end of the shaft 202, and a drive housing 208 connected to the proximal end of the shaft 202. In surgical tools and robotic surgical systems (e.g., Figure 1 In applications where the robotic surgical system 100 is used in conjunction with the robotic surgical system, the drive housing 208 may include a coupling feature that releasably couples the surgical tool 200 to the robotic surgical system.

[0024] The terms "proximal" and "distal" are defined herein with respect to a robotic surgical system having an interface configured to mechanically and electrically connect surgical tools 200 (e.g., housing 208) to a robotic manipulator. The term "proximal" refers to a location of an element closer to the robotic manipulator, and the term "distal" refers to a location of an element closer to the end effector 204 and therefore further away from the robotic manipulator. Alternatively, in manual or hand-operated applications, the terms "proximal" and "distal" are defined herein with respect to a user such as a surgeon or clinician. The term "proximal" refers to a location of an element closer to the user, and the term "distal" refers to a location of an element closer to the end effector 204 and therefore further away from the user. Furthermore, directional terms such as above, below, up, down, upward, downward, left, right, etc., are used with respect to exemplary embodiments as they are shown in the figures, with upward or upper directions pointing towards the top of the corresponding figure, and downward or lower directions pointing towards the bottom of the corresponding figure.

[0025] During use of the surgical tool 200, the end effector 204 is configured to be movable (pivoted) at the wrist 206 relative to the axis 202 to position the end effector 204 at a desired orientation and location relative to the surgical site. To achieve this, the housing 208 includes various drive inputs and mechanisms (e.g., gears, actuators, etc.) designed to control the operation of various features associated with the end effector 204 (e.g., clamping, firing, cutting, rotation, articulation, etc.). In at least some applications, the axis 202 and thus the end effector 204 coupled thereto are configured to rotate about a longitudinal axis A1 of the axis 202. In such embodiments, at least one of the drive inputs included in the housing 208 is configured to control the rotational movement of the axis 202 about the longitudinal axis A1.

[0026] Shaft 202 is an elongated member extending distally from housing 208 and has at least one lumen extending through it along its axial length. In some embodiments, shaft 202 may be fixed to housing 208, but may alternatively be rotatably mounted to housing 208 to allow shaft 202 to rotate about longitudinal axis A1. In other embodiments, shaft 202 may be releasably coupled to housing 208, which allows a single housing 208 to be adapted to various shafts with different end actuators.

[0027] The end effector 204 can exhibit a variety of sizes, shapes, and configurations. In the illustrated embodiment, the end effector 204 includes surgical scissors comprising opposing first (upper) blades 210 and second (lower) blades 212, which are configured to move (articular) between an open position and a closed position. However, as will be understood, blades 210, 212 may alternatively include opposing jaws that form part of other types of end effectors, such as, but not limited to, needle actuators, clamps, tissue grippers, vascular sealers, combined tissue clamps, and vascular sealers, including a pair of opposing gripping jaws such as a Babcock clamp, bipolar jaws (e.g., bipolar Maryland grippers, clamps, fenestrated grippers, etc.). One or both of blades 210, 212 may be configured to pivot to articulate the end effector 204 between an open position and a closed position.

[0028] Figure 3 The potential degrees of freedom of the wrist 206 to perform joint movements (pivots) and thus move the end effector 204 are shown. The wrist 206 can have any of a variety of configurations. Generally, the wrist 206 includes a joint configured to allow pivotal movement of the end effector 204 relative to axis 202. The degrees of freedom of the wrist 206 are represented by three translational variables (i.e., sway, roll, and heave) and three rotational variables (i.e., Euler angles or roll, pitch, and yaw). The translational and rotational variables describe the position and orientation of the end effector 204 relative to a given reference Cartesian coordinate system frame. Figure 3 As shown, "swaying" refers to translational motion forward and backward, "swaying" refers to translational motion up and down, and "swaying" refers to translational motion left and right. Regarding rotational terms, "rolling" refers to tilting left and right, "swaying" refers to tilting forward and backward, and "rolling" refers to turning left and right.

[0029] Pivoting motion can include a pitching motion about a first axis (e.g., the X-axis) of the wrist 206, a yaw motion about a second axis (e.g., the Y-axis) of the wrist 206, and combinations thereof, such that the end effector 204 rotates 360° about the wrist 206. In other applications, pivoting motion may be limited to movement in a single plane, such as a pitching motion only about the first axis of the wrist 206 or a yaw motion only about the second axis of the wrist 206, such that the end effector 204 moves only in a single plane.

[0030] See you again Figure 2 The surgical tool 200 may also include multiple drive cables forming part of a cable-driven motion system (in Figure 2(The system is shielded), and the cable-driven motion system is configured to facilitate actuation and articulation of the end effector 204 relative to the shaft 202. Moving one or more of the drive cables (performing articulation) causes the end effector 204 to move between a non-articulated position and an articulated position. The end effector 204 in... Figure 2 The image is shown in a non-jointed position, in which the longitudinal axis A2 of the end effector 204 is substantially aligned with the longitudinal axis A1 of the shaft 202, such that the end effector 204 forms a substantially zero angle with respect to the shaft 202. Due to factors such as manufacturing tolerances and the precision of the measuring devices, the end effector 204 may not form a precisely zero angle with respect to the shaft 202 in the non-jointed position, but it is still considered to be "substantially aligned" with it. In the jointed position, the longitudinal axes A1 and A2 will be offset at an angle to each other, such that the end effector 204 forms a non-zero angle with respect to the shaft 202.

[0031] Similar to most surgical instruments, surgical instrument 200 includes various high-wear components, referred to herein as "consumables," which may mechanically or physically deteriorate over time, thereby limiting the lifespan of surgical instrument 200. Therefore, surgical instrument 200 may be designed for use only in a predetermined number of surgeries. Once the predetermined number of surgeries is reached, the operator (e.g., nurse, doctor, etc.) may no longer be able to use surgical instrument 200. In such cases, the entire surgical instrument 200 is typically discarded, which can have an adverse environmental impact.

[0032] In some embodiments, the surgical instrument 200 may be powered (current-powered) via a power cable 214 coupled to the housing 208. In other embodiments, the power cable 214 may be omitted, and power may be supplied to the surgical instrument 200 via an internal power source, such as one or more batteries, capacitors, or fuel cells. In such embodiments, the surgical instrument 200 may alternatively be characterized as, and in other words, referred to as, an “electrosurgery instrument” capable of supplying electrical power to the end effector 204.

[0033] Power cable 214 can position surgical instrument 200 in electrical communication with a generator that supplies energy, such as electrical energy (e.g., radio frequency energy), ultrasonic energy, microwave energy, thermal energy, or any combination thereof, to surgical instrument 200 and more specifically to end effector 204. Therefore, the generator may include a radio frequency (RF) source, an ultrasonic source, a DC power supply, and / or any other suitable type of electrical energy source that can be activated independently or simultaneously.

[0034] Figure 4 This is an enlarged isometric view of the distal end of a surgical tool 200 according to one or more embodiments. More specifically, Figure 4An enlarged view of the end effector 204 and wrist 206 is depicted, with the end effector 204 in a non-articular position. The wrist 206 operatively connects the end effector 204 to the shaft 202. For this purpose, the wrist 206 includes a distal connecting fork 402a and a proximal connecting fork 402b. The end effector 204 (i.e., jaws 210, 212) is rotatably mounted at a first shaft member 404a to the distal connecting fork 402a, the distal connecting fork 402a is rotatably mounted at a second shaft member 404b to the proximal connecting fork 402b, and the proximal connecting fork 402b is connected to the distal end 406 of the shaft 202.

[0035] The wrist 206 provides a first pivot axis P1 extending through the first shaft 404a and a second pivot axis P2 extending through the second shaft 404b. The first pivot axis P1 is substantially perpendicular (or orthogonal) to the longitudinal axis A2 of the end effector 204, and the second pivot axis P2 is substantially perpendicular (or orthogonal) to both the longitudinal axis A2 and the first pivot axis P1. Movement about the first pivot axis P1 provides "yaw" articulation of the end effector 204, and movement about the second pivot axis P2 provides "pitch" articulation of the end effector 204. In the illustrated embodiment, the blades 210, 212 are mounted at the first pivot axis P1, thereby allowing the blades 210, 212 to pivot relative to each other to open and close the end effector 204, or alternatively to pivot one in front of the other to articulate the orientation of the end effector 204.

[0036] Multiple drive cables, shown as drive cables 408a, 408b, 408c, and 408d, extend longitudinally within a cavity 410 defined by shaft 202 and pass through wrist 206 to be operatively coupled to end effector 204. Although Figure 4 Four drive cables 408a to 408d are shown, but may include more or fewer than four drive cables 408a to 408d without departing from the scope of this disclosure.

[0037] Drive cables 408a to 408d can be formed and housed in drive housing 208. Figure 2 The drive cable is part of a cable-driven motion system and may include cables, belts, lines, ropes, wires, braided filaments, cords, strands, stranded wires, elongated components, conveyor belts, shafts, flexible shafts, drive rods, or any combination thereof. Drive cables 706a to 706d may be made of a variety of materials, including but not limited to metals (e.g., tungsten, stainless steel, nickel-titanium, etc.), polymers (e.g., ultra-high molecular weight polyethylene), and synthetic fibers (e.g., Kevlar). ® VECTRAN ® (etc.), elastomers, or any combination thereof. Although in Figure 4Four drive cables 408a-408d are depicted, but more or fewer than four drive cables may be used without departing from the scope of this disclosure.

[0038] Drive cables 408a to 408d extend from the end effector 204 toward the proximal side to the drive housing 208. Figure 2 These actuators are operatively coupled to various actuating mechanisms or devices housed therein to facilitate longitudinal movement (translation) of drive cables 408a to 408d within the lumen 410. Selective actuation of all or part of drive cables 408a to 408d causes articulation (pivoting) of end effectors 204 (e.g., one or both of jaws 210, 212) relative to axis 202. More specifically, selective actuation causes longitudinal translation of the corresponding drive cables 408a to 408d within the lumen 410, thereby causing pivoting of end effectors 204. One or more drive cables 408a to 408d may, for example, be longitudinally translated to cause the end effector 204 to articulate (e.g., jaws 210 and 212 are angled in the same direction), to cause the end effector 204 to open (e.g., one or both of jaws 210 and 212 move away from the other), or to cause the end effector 204 to close (e.g., one or both of jaws 210 and 212 move toward the other).

[0039] The moving drive cables 408a to 408d can be implemented in various ways, such as by being operatively coupled to the drive housing 208 or an associated actuator or mechanism housed within the drive housing. Figure 2 The movement of the given drive cables 408a to 408d constitutes the application of tension (i.e., pulling force) to the given drive cables 408a to 408d in the proximal direction, which causes the given drive cables 408a to 408d to translate, and thereby causes the end effector 204 to move relative to the shaft 202 (articular movement).

[0040] The wrist 206 includes a plurality of first pulleys 412a and a plurality of second pulleys 412b, each pulley configured to interact with and redirect drive cables 408a to 408d for engagement with end effector 204. The plurality of first pulleys 412a are mounted at a second axle 404b to a proximal connecting fork 402b, and the plurality of second pulleys 412b are also mounted to a proximal connecting fork 402b, but at a third axle 404c located proximal to the second axle 404b. Before the drive cables 408a to 408d are operatively engaged with end effector 204, the plurality of first pulleys 412a and the plurality of second pulleys 412b cooperatively redirect the drive cables 408a to 408d through an “S”-shaped path.

[0041] In at least one embodiment, a pair of drive cables 408a to 408d are operatively coupled to each jaw 210, 212 and configured to operate the corresponding jaws 210, 212 in an antagonistic manner. In the illustrated embodiment, for example, a first drive cable 408a and a second drive cable 408b are coupled to (terminate at) a first blade 210, and a third drive cable 408c and a fourth drive cable 408d are coupled to (terminate at) a second blade 212. Actuation of the first drive cable 408a is applied to the first blade 210, causing the first blade 210 to pivot about a first pivot axis P1 toward a closed position. In contrast, actuation of the second drive cable 408b is applied to the first blade 210, causing the first blade 210 to pivot about the first pivot axis P1 toward an open position. Similarly, actuation of the third drive cable 408c causes the second blade 212 to pivot about the first pivot axis P1 toward the closed position, while actuation of the fourth drive cable 408d causes the second blade 212 to pivot about the first pivot axis P1 toward the open position.

[0042] Therefore, drive cables 408a to 408d can be characterized as, or otherwise referred to as, “antagonistic” cables, which operate cooperatively (but antagonistically) to cause relative or tandem movement of the first jaw 210 and the second jaw 212. When the first drive cable 408a is actuated (moved), the second drive cable 408b naturally follows, and vice versa, since it is also connected to the first blade 210. Similarly, when the third drive cable 408c is actuated, the fourth drive cable 408d naturally follows, and vice versa, since it is also connected to the second blade 210.

[0043] The surgical tool 200 may also include an electrical conductor 414 that supplies electrical power to the end effector 204, thereby converting the surgical tool 200 into an "electrosurgical instrument". However, in other embodiments, the electrical conductor 414 may be omitted, and the end effector 204 may operate solely as surgical scissors. However, in embodiments where the end effector 204 includes an electrosurgical instrument, the electrical conductor 414 extends longitudinally within the lumen 410 and passes through the wrist 206 to be operatively (and electrically) coupled to the end effector 204. In some embodiments, the electrical conductor 414 and the power cable 214 ( Figure 2 The same structure may be included. However, in other embodiments, the electrical conductor 414 may be electrically connected to the power cable 214. In other embodiments, the electrical conductor 414 may extend to the drive housing 208. Figure 2 The electrical conductors there are electrically connected to an internal power source, such as a battery or fuel cell.

[0044] Electrical conductor 414 may include a power supply conductor 416 encapsulated by an insulating cover (e.g., insulated wire). In the illustrated embodiment, end effector 204 is configured for unipolar operation. Electrical energy is thus transferred from power supply conductor 416 to end effector 204, which acts as an active (or source) electrode. In at least one embodiment, the electrical energy may include radio frequency (“RF”) energy exhibiting frequencies between about 100 kHz and 1 MHz. Low-frequency RF energy causes ion agitation or friction, effectively resistive heating, thereby increasing the temperature of the target tissue. Therefore, the electrical energy supplied to end effector 204 is converted into heat and transferred to adjacent tissue to cut, cauterize, and / or coagulate the tissue (depending on localized heating of the tissue), and can thus be particularly used to seal blood vessels or diffuse bleeding. The electrical energy is then returned from the tissue via a return electrode, which typically comprises a grounding pad located separately on the patient's body.

[0045] Figure 5A and Figure 5B These are based on one or more implementation schemes. Figure 4 Enlarged left and right isometric views of the end effector 204. As described above, the end effector 204 includes a first blade 210 and a second blade 212 rotatably mounted at a first shaft 404a to a distal connecting fork 402a. (The remaining text is omitted.) Figure 4 Drive cables 408a to 408d are provided to allow for better observation of the components of the end effector 204.

[0046] As illustrated, the end effector 204 also includes a first blade holder 502a and a second blade holder 502b rotatably mounted to the first shaft 404a and laterally offset from each other. The first blade holder 502a is configured to receive and hold the first blade 210 such that movement (rotation) of the first blade holder 502a about the first pivot axis P1 correspondingly moves (rotates) the first blade 210. The first blade holder 502a may also be provided with and otherwise define a first pulley 504a, which is configured to receive and hold one or more drive cables, such as Figure 4 The third drive cable 408c and the fourth drive cable 408d are used to achieve this movement (rotation). The second blade holder 502b is configured to receive and hold the second blade 212 such that movement (rotation) of the second blade holder 502b about the first pivot axis P1 correspondingly causes the second blade 212 to move (rotate). The second blade holder 502b may also be provided with and otherwise define a second pulley 504b, which is configured to receive and hold one or more drive cables, such as Figure 4 The first drive cable 408a and the second drive cable 408b are used to achieve this kind of movement (rotation).

[0047] As used herein, the term "blade retainer" is intended to apply to various types of end effectors having opposing blades or jaws that can move relative to each other. In the illustrated embodiments, blades 210, 212 comprise opposing scissor blades of a surgical scissor end effector. However, in other embodiments, blades 210, 212 may alternatively comprise opposing jaws for gripper end effectors, etc., and the term "jaw retainer" applies similarly without departing from the scope of this disclosure. Furthermore, the term "retainer" in the term "jaw retainer" can be replaced with a "mount," a "drive member," or an "actuator."

[0048] In some embodiments, the first blade holder 502a and the second blade holder 502b may be made of electrically insulating or non-conductive materials. Suitable non-conductive materials include, but are not limited to, ceramics (e.g., zirconium oxide, alumina, aluminum nitride, silicates, silicon nitride, etc.), high-temperature and high-strength plastics, and thermoplastic or thermosetting polymers (e.g., polyetheretherketone, ULTEM). ™ VESPEL ® Polyphenylsulfone, polysulfone, RADEL ® Polyamide-imide, polyimide, epoxy resin, etc., composite materials (e.g., glass fiber), hard rubber (e.g., hard rubber), or any combination thereof. Alternatively, the proximal regions of the blades 210, 212 may be coated with a non-conductive material (e.g., ceramic) to isolate the proximal regions of the blades 210, 212 from the blade holders 502a, 502b, which isolate the blades 210, 212 from the remainder of the wrist components, thereby allowing these wrist components to be constructed of conventional conductive materials such as stainless steel.

[0049] In some embodiments, the first blade holder 502a and the second blade holder 502b may each comprise an integral structure made of a common (single) material. However, in other embodiments, one or both of the blade holders 502a and 502b may comprise two or more portions joined together to form the blade holders 502a and 502b. In such embodiments, for example, the first portion of the blade holders 502a and 502b may be configured to receive blades 210 and 212, and the second portion may provide corresponding pulleys 504a and 504b. Furthermore, in such embodiments, the first and second portions may be made of the same material or different materials. For example, the first portion may be made of a non-conductive material (e.g., ceramic or polymer), and the second portion may be made of a different non-conductive material or alternatively, a conductive material. In other embodiments, the first and second portions may be made of different non-conductive materials. In such embodiments, the first portion may be made of ceramic, and the second portion may be made of plastic overmolded onto and otherwise bonded to the first portion.

[0050] Figure 6A and Figure 6B These are based on one or more implementation schemes. Figures 5A to 5B The exploded left and right isometric views of the end effector 204. More specifically, Figures 6A to 6B The blades 210, 212 and their corresponding blade holders 502a, 502b are shown to be removed and disassembled from the first shaft 404a, and the first shaft 404a is disassembled from the distal connecting fork 402a.

[0051] As illustrated, the first blade 210 includes a first protrusion 602a ( Figure 6B The first protrusion is configured to be received in the first arcuate slot 604a defined in the second blade 212 when the blades 210, 212 and the corresponding blade holders 502a, 502b are mounted to the first shaft 404a. Figure 6A Similarly, the second blade 212 includes a second protrusion 602b. Figure 6A The second protrusion is configured to be received in the second arcuate slot 604b defined in the first blade 212 when the blades 210, 210 and the corresponding blade holders 502a, 502b are mounted to the first shaft 404a. Figure 6B Inside. Receiving the protrusions 602a and 602b into the corresponding arcuate slots 604b and 604a helps prevent the blades 210 and 212 from rotating excessively during operation (in both angular directions).

[0052] The distal connecting fork 402a provides opposing first arms 606a and second arms 606b, which are laterally offset from each other and extend distally from the body 608. A space or gap 610 is formed between the arms 606a, 606b and is sized to receive combined blades 210, 212 and blade holders 502a, 502b when mounted to the first shaft 404a. Each arm 606a, 606b provides and otherwise defines a slot 612 with an end opening that opens in the distal direction, and each slot 612 is configured to receive and accommodate opposing ends of the first shaft 404a. In some embodiments, as illustrated, each slot 612 may define a minimized section 614 that leads to an enlarged section 616. Compared to the enlarged section 616, the minimized section 614 provides a smaller clearance (space), and therefore, the first shaft 404a may need to be forced through the minimized section 614 before reaching the enlarged section 616 and otherwise disassembled from the distal connecting fork 402a. This can prove advantageous in helping to prevent the first shaft 404a from unintentionally disengaging from the slot 612 during operation. Therefore, the end-opening slot 612 can be configured to provide a snap-fit ​​or interference fit that allows the first shaft 404a to move distally after force is applied.

[0053] In some embodiments, a longitudinal slit 618 may be defined in each arm 606a, 606b, adjacent to and extending away from the corresponding slot 612 in the proximal direction. The slit 618 introduces a weak point for each arm 606a, 606b, thereby allowing the opposite portion of each arm 606a, 606b at the slot 612 to flex outward when the first shaft 404a is forced through the minimized segment 614 to receive the first shaft 404a or to remove it from the slot 612.

[0054] In some embodiments, the first shaft 404a may be keyed at or near one or both ends. More specifically, as illustrated, the first shaft 404a may be provided with a disassembly feature 620 at each end, which is configured to align with a slot 612 of an end opening. In the illustrated embodiment, the disassembly feature 620 includes opposing sections of the first shaft 404a, which is reduced in size by providing opposing planar (flat) surfaces, in contrast to a circular cross-section.

[0055] If the disassembly feature 620 is oriented together with the longitudinal direction of the end-opening slot 612, the disassembly feature 620 can facilitate allowing the first shaft 404a to more easily bypass the minimized section 614. Therefore, in some embodiments, the first shaft 404a can be rotated first until the disassembly feature 620 is aligned with the longitudinal direction of the end-opening slot 612 before it can be removed from the end-opening slot 612.

[0056] Figure 7A and Figure 7B These are based on one or more implementation schemes. Figures 5A to 5B Enlarged, exploded left and right isometric views of the end effector 204. More specifically, Figures 7A to 7B The blades 210 and 212, separated from the corresponding blade holders 502a and 502b, are depicted, and the washer 702, separated from the first shaft 404a, is further depicted.

[0057] As illustrated, each blade holder 502a, 502b defines a first recess 704a configured to receive and accommodate a corresponding blade 210, 212, such that movement (rotation) of the blade holders 502a, 502b will correspondingly cause movement (rotation) of the corresponding blade 210, 212. Each blade holder 502a, 502b may further define a second recess 704b defined within the first recess 704a and otherwise deeper into the material of the blade holders 502a, 502b. Each second recess 704b may be configured to receive a portion of the first shaft 404a. More specifically, the second recess 704b defined in the first blade holder 502a may be configured to receive an enlarged radial shoulder 706 defined on the first shaft 404a and otherwise forming a portion of the first shaft. In contrast, the second recess 704b defined in the second blade holder 502b can be configured to receive the washer 702. As will be understood, without departing from the scope of this disclosure, the orientation of the first shaft 404a can be switched such that the enlarged radial shoulder 706 is alternatively received within the second recess 704b of the second blade holder 502b, and the washer 702 is received within the second recess 704b of the first blade holder 502a.

[0058] Each blade 210, 212 defines a center bore 708, which is coaxially aligned with a shaft bore 710 defined in a corresponding blade holder 502a, 502b. The center bore 708 and the shaft bore 710 are configured to receive a portion of a first shaft 404a. Furthermore, in some embodiments, the diameter of the center bore 708 may be larger than the diameter of the shaft bore 710. This allows the blades 210, 212 to be mounted to the first shaft 404a at a bushing 712 defined by the first shaft 404a.

[0059] When the blades 210, 212 are properly mounted to the first shaft 404a at the bushing 712, an enlarged radial shoulder 706 is arranged on one side of the blades 210, 212, and a washer 702 is arranged on the opposite side of the blades 210, 212. With the blades 210, 212 mounted to the first shaft 404a and pushed upward against the enlarged radial shoulder 706, the washer 712 can then be received on and secured (welded) to the first shaft 404a. In at least one embodiment, the washer 702 can be secured to the bushing 712. Securing the washer 702 to the first shaft 404a axially secures the blades 210, 212 to the first shaft 404a, but simultaneously allows the blades 210, 212 to rotate relative to each other during operation of the end effector 204.

[0060] The end effector 204 includes various high-wear components that can mechanically or physically deteriorate over time, thereby limiting the service life of the end effector 204. For example, drive cables 408a to 408d ( Figure 4 The end effector 204 and surgical tool 200 may fatigue over time, which could affect their performance. Figure 2 The precision and operability of the end effector 204 are affected. Similarly, the cutting edges of blades 210 and 212 can become dull over time, which may also affect the proficiency of the end effector 204. Therefore, the end effector 204 may be designed to be used only for a predetermined number of procedures, and once the predetermined number of procedures is reached, the operator (e.g., nurse, doctor, etc.) may no longer be able to use the end effector 204. In such cases, the surgical instrument 200 is often discarded, which may have an adverse impact on the environment.

[0061] According to embodiments of this disclosure, instead of discarding the end effector 204, the end effector 204 can be disassembled and its high-wear components (e.g., blades 210, 212) can be replaced. The end effector 204 can then be reassembled and reused. As described herein, blades 210, 212 can be removed and replaced from the remainder of the end effector 204 as needed, potentially providing users (e.g., surgeons, nurses, etc.) with a new set of blades 210, 212 for use with surgical instrument 200. Figure 2 Each new use of ).

[0062] Figures 8 to 11 The progressive steps for disassembling the end effector 204 according to an embodiment of this disclosure are described. Figure 8 In the assembly state, the end effector 204 is in the assembled state, wherein the blades 210, 212 and the corresponding blade holders 502a, 502b are rotatably mounted at the first shaft 404a to the distal connecting fork 402a, as generally described above. Figure 8 The image shows blades 210 and 212 in the closed position. In some embodiments, the surgical tool 200 (…) is used before the disassembly process of the end effector 204 begins. Figure 2 ) drive housing 208 ( Figure 2 The drive cables 408a to 408d can be detached from the robot manipulator first. As described below, detachment from the robot manipulator allows the drive cables 408a to 408d to be released (e.g., cable length distribution) without being obstructed by the drive output of the robot manipulator's motor.

[0063] exist Figure 9 In this process, the end effector 204 transitions from an assembled state to an extended state. More specifically, the end effector 204 moves distally, as indicated by arrow B, thereby disengaging the first shaft 404a from the distal connecting fork 402a. In at least one embodiment, this can be manually accomplished by an operator by manually grasping the blade holders 502a, 502b and removing the first shaft 404a from the slot 612 of the end opening in the distal direction B. This movement effectively separates the end effector 204 from the distal connecting fork 402a. Disengaging the first shaft 404a from the distal connecting fork 402a involves forcing the first shaft 404a away from the slot 612 of the end opening. In some embodiments, the disassembly feature 620, defined at or near each or both ends of the first shaft 404a, can initially be rotated to its "original" orientation, wherein the disassembly feature 620 is aligned with the longitudinal direction of the slot 612 of the end opening.

[0064] Once the disassembly feature 620 is angled back to its original orientation, the end effector 204 can be manually moved distally to B to disengage the end effector 204 from the distal connecting fork 402a. In at least one embodiment, a load of at least 11.5 Newtons may be required to force the first shaft 404a out of the slot 612 and otherwise transform the end effector 204 into its extended state. As will be understood, the design and configuration of the slot 612 can be adjusted to any desired preload.

[0065] In order to enable the distal end effector 204 to be pulled distally, the surgical tool 200 ( Figure 2) can be found in drive housing 208 ( Figure 2 A slack portion may be provided at the location or otherwise incorporated into the design. More specifically, drive cables 408a to 408d may each be configured to release a “slack portion” when the end effector 204 is pulled toward the distal B. In at least one embodiment, this can be achieved by rotating an input winch arranged within the drive housing 208 and associated with each drive cable 408a to 408d. Rotating the input winch can be done manually by physically engaging and rotating the input winch, or alternatively by pulling the end effector 204 toward the distal B. As the input winch rotates, drive cables 408a to 408d may be able to unwind or “release” the cable via various winding winch mechanisms.

[0066] exist Figure 10 Once the end effector 204 has moved to the extended state, the blade holders 502a and 502b can then be separated from the blades 210 and 212, respectively. More specifically, the blade holders 502a and 502b can be laterally displaced from the blades 210 and 212 in opposite lateral directions, as indicated by arrow C. The blade holders 502a and 502b can be laterally displaced by C until they disengage from the first shaft 404a.

[0067] exist Figure 11 Once the blade holders 502a and 502b disengage from the first shaft 404a, the blades 210 and 212 and the shaft 404a can be removed (separated) from the remainder of the end effector 204. The separated blades 210, 212 and the shaft 404a will be collectively referred to herein as the "blade set" 1100. The blade set 1100 can then be refurbished or completely replaced with a new blade set.

[0068] Figure 12 This is an enlarged isometric view of the assembly of a new blade assembly 1200 according to one or more embodiments of this disclosure. As illustrated, the blade assembly 1200 includes a first blade 210 and a second blade 212, a first shaft 404a, and a washer 702. In some embodiments, the blade assembly 1200 may be assembled in the end effector 204 prior to disassembly. Figures 8 to 11 The same set of blades used in the present invention. In such embodiments, and prior to reassembly, blades 210, 212 may have been refurbished and / or resharpened. However, in other embodiments, without departing from the scope of this disclosure, blade set 1200 may include a completely or partially new set of blades.

[0069] To assemble the blade assembly 1200, blades 210, 212 can first be mounted to the first shaft 404a at the bushing 710. More specifically, the bushing 710 can be received within the center bore 708 of each blade 210, 212, and the second blade 212 can be pushed upward against an enlarged radial shoulder 706 (which is largely blocked). A washer 702 can then be mounted to the first shaft 404a and pushed against the first blade 210 opposite the enlarged radial shoulder 706. As illustrated, the washer 702 includes a center bore 1204 sized to receive the first shaft 404a. In some embodiments, as illustrated, the center bore 1204 can be sized to receive the bushing 710. Once placed against the first blade 210, the washer 702 can be secured to the first shaft 404a, such as by welding it to the first shaft 404a at the interface 1204 between the bushing 710 and the center hole 1204.

[0070] Assemble the new or refurbished blade assembly 1200, and then the aforementioned disassembly and separation steps of the end effector 204 can be reversed to remove the surgical tool 200 ( Figure 2 It has been put back into use. Specifically, in relation to the above... Figure 10 and Figure 11 In the reverse process described in the text, the blade holders 502a and 502b can be mounted on the opposite side of the blade assembly 1200 to the first shaft 404a.

[0071] In Figure 9 In the reverse process described herein, the end effector 204 can then be transformed back to the assembled state. To achieve this, the first shaft 404a is aligned with the slot 612 of the end opening of the distal connecting fork 402a, and the end effector 204 moves proximally to receive the opposite end of the first shaft 404a in the slot 612. In some embodiments, the disassembly feature 620 defined at or near each end of the first shaft 404a can first be rotated to its original orientation, in which the disassembly feature 620 is aligned with the longitudinal direction of the slot 612 of the end opening. Then, the slack portion in the drive cables 408a to 408d can be removed from the drive housing 208 ( Figure 2 It is absorbed at ) location.

[0072] Figure 13A and Figure 13BThese are enlarged isometric and exploded views, respectively, of the end effector 204 according to one or more additional embodiments of the present disclosure. As generally described above, the disassembly feature 620 may be defined at or near one or both ends of the first shaft member 404a. In the illustrated embodiment, the disassembly feature 620 includes opposing sections of the first shaft member 404a that are reduced in size by providing opposing planar (flat) surfaces, in contrast to a circular cross-section.

[0073] When the disassembly feature 620 is oriented together with the longitudinal direction of the slot 612 of the end opening, the first shaft 404a can more easily bypass the minimized section 614 of the slot 612 of the end opening. In the illustrated embodiment, aligning the disassembly feature 620 with the longitudinal direction of the slot 612 of the end opening can be achieved by engaging and manipulating one or more external keys 1302 defined on one or both ends of the first shaft 404a. In at least one embodiment, the external key 1302 may include a channel or slit defined in the end face of the first shaft 404a. In such embodiments, an operator may be able to insert a flat-head tool, such as a flat-head screwdriver (not shown), and manually rotate the first shaft 404a to the appropriate angular orientation.

[0074] exist Figure 13B In this process, end effector 204 transitions from an assembled state to an extended state, wherein end effector 204 moves distally, as indicated by arrow B, thereby disengaging the first shaft 404a from the distal connecting fork 402a. Disengaging the first shaft 404a from the distal connecting fork 402a includes forcing the first shaft 404a away from the slot 612 of the end opening. Before disengaging the first shaft 404a from the distal connecting fork 402a, an operator can manually engage the external key 1302 and rotate the first shaft 404a until the disassembly feature 620 is rotated to its "original" orientation, wherein the disassembly feature 620 is aligned with the longitudinal direction of the slot 612 of the end opening. Once the disassembly feature 620 is angled to its original orientation, end effector 204 can be manually moved distally B to separate end effector 204 from the distal connecting fork 402a.

[0075] Figure 14A and Figure 14BThese are enlarged isometric and exploded views, respectively, of an end effector 204 according to one or more additional embodiments of the present disclosure. In some embodiments, a first shaft 404a is operatively coupled to one of the blades 210, 212 and otherwise forms an integral portion of one of the blades 210, 212. In the illustrated embodiment, the first shaft 404a forms an integral portion of a first jaw 210. In such embodiments, rotation of the first jaw 210 will correspondingly cause the first shaft 404a to rotate in the same angular direction.

[0076] In the illustrated embodiment, the disassembly feature 620 is defined on one or both ends of the first shaft 404a such that the disassembly feature 620 is aligned with the longitudinal direction of the slot 612 of the end opening at an angle outside the normal operating range of the end actuator 204. In the illustrated embodiment, for example, the first jaw 210 must rotate substantially perpendicular to the longitudinal direction of the slot 612 of the end opening to align the disassembly feature 620 with said longitudinal direction. In such embodiments, the jaws 210, 212 can be designed to never be perpendicular to the longitudinal direction of the slot 612 of the end opening during operation. This ensures that the first shaft 404a cannot be removed from the slot 612 of the end opening in any other angular position.

[0077] exist Figure 14B In this process, the end effector 204 transitions from an assembled state to an extended state, wherein the end effector 204 moves distally, as indicated by arrow B, thereby disengaging the first shaft 404a from the distal connecting fork 402a. As indicated, the jaws 210 must first rotate until the disassembly feature 620 is angled to the longitudinal direction of the slot 612 of the end opening. Disengaging the first shaft 404a from the distal connecting fork 402a then involves forcing the first shaft 404a away from the slot 612 of the end opening.

[0078] The implementation plan disclosed in this article includes: A. A method for replacing the blade of an end effector of a surgical instrument, the method comprising: moving the end effector distally from an assembled state to an extended state, wherein in the assembled state the end effector is rotatably mounted to a connecting fork at the wrist of the surgical instrument, and in the extended state a shaft of the end effector is displaced from a slot defining an end opening in opposing first and second arms of the connecting fork, the end effector comprising: opposing first and second blades; and a first blade holder and a second blade holder rotatably mounted to the shaft, the first blade being mounted to the first blade holder and the second blade being mounted to the second blade holder. The method further includes: separating the first blade holder and the second blade holder from the first blade and the second blade in opposite lateral directions until the first blade holder and the second blade holder are removed from the shaft; removing the first blade and the second blade and the shaft from the remaining portion of the end effector; assembling a new blade assembly, the new blade assembly including a new first blade and a new second blade and a new shaft; mounting the first blade holder and the second blade holder to the new shaft, thereby mounting the new first blade and the new second blade to the first blade holder and the second blade holder, respectively; and moving the end effector proximally and returning it to the assembled state by receiving the new shaft within a slot in the end opening.

[0079] B. A surgical instrument comprising: a drive housing; an elongated shaft extending distally from the drive housing; a wrist disposed at a distal end of the shaft and including: a connecting fork providing a body and opposing first and second arms extending distally from the body; and end-opening slots defined in each arm and opening in a distal direction. The surgical instrument further comprises: an end effector operatively coupled to the wrist and including: a shaft mounted to the connecting fork at each end-opening slot, each end of the shaft providing a disassembly feature alignable with the longitudinal direction of each end-opening slot; and opposing first and second blades rotatably mounted to the shaft.

[0080] C. An end effector for a surgical instrument, the end effector comprising: a connecting fork providing a body and opposing first and second arms extending distally from the body; a slot for an end opening defined in each arm and opening in a distal direction, each end opening slot defining a minimized section leading to an enlarged section, the minimized section providing a smaller clearance compared to the enlarged section; a shaft mounted to the connecting fork at each end opening slot; a first blade holder and a second blade holder rotatably mounted to the shaft; a first blade mounted to the first blade holder; and a second blade mounted to the second blade holder, wherein the first blade holder and the second blade holder, as well as the first blade and the second blade, are separable from the connecting fork by forcing the shaft to exit in the distal direction from the slot of the end opening of each arm.

[0081] Each of embodiments A, B, and C may have one or more of the following additional elements in any combination: Element 1: wherein moving the end effector from the assembled state toward the extended state comprises: manually grasping the end effector and moving the shaft out of the slot of the end opening in the distal direction. Element 2: wherein the slot of each end opening defines a minimized section leading to an enlarged section, the minimized section providing a smaller clearance compared to the enlarged section, and wherein moving the end effector from the assembled state toward the extended state further comprises: forcing the shaft through the minimized section and out of the slot of the end opening. Element 3: wherein the shaft provides opposing planar surfaces at each end, and the opposing planar surfaces are aligned with the longitudinal direction of the slot of each end opening before forcing the shaft through the minimized section. Element 4: Each end of the shaft is provided with a disassembly feature, and the shaft is rotated to its original orientation before moving the end effector from the assembled state to the extended state, in which the disassembly feature is aligned with the longitudinal direction of the slot of the end opening. Element 5: A plurality of drive cables extend from the drive housing of the surgical tool and terminate at the first blade holder and the second blade holder, and moving the end effector from the assembled state to the extended state includes: releasing a slack portion of the plurality of drive cables from the drive housing as the end effector moves distally. Element 6: Separating the first blade holder and the second blade holder from the first blade and the second blade in opposite lateral directions includes: retaining the plurality of drive cables attached to the blade holder when the first blade holder and the second blade holder are removed from the shaft. Element 7: Wherein, assembling the new blade assembly includes: receiving the new shaft within a central hole defined in each of the new blades; advancing the first and second blades along the new shaft until a first side of the new first and second blades engages an enlarged radial shoulder defined by the new shaft; mounting a washer on the shaft and engaging a second side of the first and second blades with the washer; and securing the washer to the new shaft. Element 8: Wherein, before moving the end effector from the assembled state distally to the extended state, the drive housing of the surgical tool is disengaged from the robot manipulator.

[0082] Element 9: Wherein, the slot of each end opening defines a minimized section leading to an enlarged section, the minimized section providing a smaller clearance compared to the enlarged section. Element 10: Wherein, the disassembly feature includes opposing planar surfaces capable of being aligned with the longitudinal direction of the slot of each end opening to force the shaft member away from the slot of the end opening. Element 11: Further includes a longitudinal slit defined in each arm and abutting and extending from the slot of the corresponding end opening in the proximal direction, wherein, when the shaft member is forced away from the slot of the corresponding end opening, the longitudinal slit allows the portion of each arm opposite the slot of the corresponding end opening to flex outward. Element 12: Wherein, the end actuator is capable of disengaging from the connecting fork by forcing the shaft member away from the slot of the end opening of each arm in the distal direction. Element 13: Further includes a first blade holder and a second blade holder, rotatably mounted to the shaft, the first blade being mounted to the first blade holder and the second blade being mounted to the second blade holder; and a plurality of drive cables extending from the drive housing and terminating at the first and second blade holders, wherein the end effector is disengaged from the connecting fork by forcing the shaft to exit in the distal direction from a slot in the end opening of each arm, and wherein the first and second blades are disengaged from the first and second blade holders respectively, while the plurality of drive cables remain attached to the first and second blade holders. Element 14: wherein the first blade holder defines a first pulley configured to receive a first and a second drive cable of the plurality of drive cables, and the second blade holder defines a second pulley configured to receive a third and a fourth drive cable of the plurality of drive cables. Element 15: wherein the shaft includes an enlarged radial shoulder, and the first blade and the second blade are fixed to the shaft, located between the enlarged radial shoulder on a first side and a washer fixed to the shaft on a second side.

[0083] Element 16: Each end of the shaft is provided with a disassembly feature including opposing planar surfaces capable of being aligned with the longitudinal direction of a slot in each end opening to force the shaft out of the slot in the end opening. Element 17: Also includes a washer capable of being mounted to the shaft, wherein the first blade and the second blade are secured to the shaft, located between the enlarged radial shoulder on a first side and the washer on a second side.

[0084] As a non-limiting example, exemplary combinations applicable to A, B, and C include: element 1 and element 2; element 2 and element 3; element 5 and element 6; element 9 and element 10; element 10 and element 11; and element 13 and element 14.

[0085] Therefore, the systems and methods disclosed herein are highly suitable for achieving the aforementioned results and advantages, as well as those inherent therein. The specific embodiments disclosed above are merely illustrative, as the teachings of this disclosure can be modified and implemented in different but equivalent ways that will be apparent to those skilled in the art. Furthermore, there are no limitations on the details of the constructions or designs shown herein, except as described in the following claims. It will therefore be apparent that the specific illustrative embodiments disclosed above can be altered, combined, or modified, and all such changes are considered to be within the scope of this disclosure. The systems and methods illustratively disclosed herein can be suitably implemented in the absence of any elements not specifically disclosed herein and / or any optional elements disclosed herein. While compositions and methods are described according to the terms “comprising,” “containing,” or “including,” the composition and methods may also be “substantially composed of various components or steps” or “composed of various components or steps.” All numerical values ​​and ranges disclosed above may vary in some quantities. Whenever a numerical range with a lower and upper limit is disclosed, any numerical value falling within that range and any included range are specifically disclosed. Specifically, each range of values ​​disclosed herein (in the form of "about a to about b" or equivalent "about a to b" or equivalent "from about ab") should be understood to list each numerical value and range covered within a broader range of values. Furthermore, the terms in the claims have their ordinary, general meaning unless otherwise expressly and clearly defined by the patentee. Additionally, the indefinite articles "a" or "an" used in the claims are defined herein as referring to one or more elements introduced therein, rather than a single element. If the use of words or terms in this specification conflicts in any way with one or more patents or other documents that may be incorporated herein by reference, the definitions consistent with this specification shall prevail.

[0086] As used herein, the phrase "at least one of..." preceding a series of items (separated by the terms "and" or "or") modifies the list as a whole, not each member of the list (i.e., each item). The phrase "at least one of..." allows for the meaning of at least one of any of the items, and / or at least one of any combination of items, and / or at least one of each of the items. As an example, the phrases "at least one of A, B, and C" or "at least one of A, B, or C" respectively mean: only A, only B, or only C; any combination of A, B, and C; and / or at least one of each of A, B, and C.

Claims

1. A method of replacing a blade of an end effector of a surgical tool, the method comprising: moving the end effector distally from an assembled state in which the end effector is rotatably mounted to a clevis of a wrist of the surgical tool to an extended state in which a shaft of the end effector is moved out of an end opening slot defined in opposing first and second arms of the clevis, the end effector including: opposing first and second blades; and first and second blade retainers that are rotatably mounted to the shaft, the first blade being mounted to the first blade retainer and the second blade being mounted to the second blade retainer; separating the first and second blade retainers from the first and second blades in opposite lateral directions until the first and second blade retainers are removed from the shaft; removing the first and second blades and the shaft from the remainder of the end effector; assembling a new blade set including a new first blade and a new second blade and a new shaft; mounting the first and second blade retainers to the new shaft and thereby mounting the new first and second blades to the first and second blade retainers, respectively; and moving the end effector proximally and back to the assembled state by receiving the new shaft within the end opening slot.

2. The method of claim 1, wherein, Moving the end effector distally from the assembled state to the extended state includes manually grasping the end effector and moving the shaft out of the end opening slot in a distal direction.

3. The method of claim 1 or 2, wherein, Each end opening slot defines a minimized section that leads to an enlarged section that provides a smaller gap compared to the enlarged section, and wherein moving the end effector distally from the assembled state to the extended state further includes forcing the shaft through the minimized section and out of the end opening slot.

4. The method of claim 3, wherein, The shaft provides opposing planar surfaces at each end, and prior to forcing the shaft through the minimized section, the opposing planar surfaces are aligned with a longitudinal direction of each end opening slot.

5. The method of any preceding claim, wherein, Each end of the shaft provides a disassembly feature, and wherein prior to moving the end effector distally from the assembled state to the extended state, the shaft is rotated to a home orientation in which the disassembly feature is aligned with a longitudinal direction of the end opening slot.

6. The method of any preceding claim, wherein, A plurality of drive cables extend from a drive housing of the surgical tool and terminate at the first and second blade holders, and wherein moving the end effector from the assembled state distally to the extended state comprises paying out slack portions of the plurality of drive cables from the drive housing as the end effector is moved distally.

7. The method of claim 6, wherein, Separating the first and second blade holders from the first and second blades in opposite lateral directions comprises maintaining the plurality of drive cables attached to the blade holders as the first and second blade holders are removed from the shaft.

8. The method of any preceding claim, wherein, Assembling the new blade set comprises: receiving the new shaft within a central aperture defined in each of the new blades; advancing the first and second blades along the new shaft until first sides of the new first and second blades engage an enlarged radial shoulder defined by the new shaft; installing a washer on the shaft and engaging second sides of the first and second blades with the washer; and securing the washer to the new shaft.

9. The method of any preceding claim, wherein, Decoupling a drive housing of the surgical tool from a robotic manipulator prior to moving the end effector from the assembled state distally to the extended state.

10. A surgical tool, comprising: a drive housing; an elongate shaft extending distally from the drive housing; a wrist arranged at a distal end of the shaft and comprising: a clevis providing a body and opposing first and second arms extending distally from the body; and an end-opening slot defined in each arm and opening in a distal direction; and an end effector operatively coupled to the wrist and comprising: a shaft member installed to the clevis at each end-opening slot, each end of the shaft member providing a disassembly feature alignable with a longitudinal direction of each end-opening slot; and opposing first and second blades rotatably mounted to the shaft member.

11. The surgical tool of claim 10, wherein, Each end-opening slot defines a minimized section leading to an enlarged section, the minimized section providing a smaller gap compared to the enlarged section.

12. The surgical tool of claim 10 or 11, wherein, The disassembly feature comprises opposing planar surfaces alignable with the longitudinal direction of each end-opening slot to force the shaft member out of the end-opening slot.

13. The surgical tool of any of claims 10 to 12, further comprising a longitudinal slit defined in each arm and contiguous with and extending from a corresponding end-opening slot in a proximal direction, and wherein The longitudinal slit allows an opposite portion of each arm to flex outwardly from the corresponding end-opening slot as the shaft member is forced out of the corresponding end-opening slot.

14. The surgical tool of any one of claims 10 to 13, wherein, The end effector is separable from the clevis by forcing the shaft out of the end opening slot of each arm in the distal direction.

15. The surgical tool of any of Claims 10 to 14, further comprising: a first blade holder and a second blade holder rotatably mounted to the shaft, the first blade mounted to the first blade holder and the second blade mounted to the second blade holder; and a plurality of drive cables extending from the drive housing and terminating at the first and second blade holders, wherein the end effector is separable from the clevis by forcing the shaft out of the end opening slot of each arm in the distal direction, and wherein the first and second blades are separable from the first and second blade holders, respectively, while the plurality of drive cables remain attached to the first and second blade holders.

16. The surgical tool of claim 15, wherein, The first blade holder defines a first pulley configured to receive first and second drive cables of the plurality of drive cables and the second blade holder defines a second pulley configured to receive third and fourth drive cables of the plurality of drive cables.

17. The surgical tool of any one of claims 10 to 16, wherein, The shaft includes an enlarged radial shoulder and the first and second blades are fixed to the shaft between the enlarged radial shoulder on a first side and a washer fixed to the shaft on a second side.

18. An end effector for a surgical tool, the end effector comprising: a clevis providing a body and opposing first and second arms extending distally from the body; an end opening slot defined in each arm and opening in a distal direction, each end opening slot defining a minimized section leading to an enlarged section, the minimized section providing a smaller gap compared to the enlarged section; a shaft mounted to the clevis at each end opening slot; a first blade holder and a second blade holder rotatably mounted to the shaft; a first blade mounted to the first blade holder; and a second blade mounted to the second blade holder, wherein the first and second blade holders and the first and second blades are separable from the clevis by forcing the shaft out of the end opening slot of each arm in the distal direction.

19. The end effector of Claim 18, wherein, Each end of the shaft provides a disassembly feature including opposing planar surfaces alignable with a longitudinal direction of each end opening slot to force the shaft out of the end opening slot. The shaft includes an enlarged radial shoulder and the first and second blades are fixed to the shaft between the enlarged radial shoulder on a first side and a washer fixed to the shaft on a second side.

20. The surgical tool of claim 18 or 19, further comprising a washer mountable to the shaft, wherein, The first and second blades are fixed to the shaft between the enlarged radial shoulder on a first side and the washer on a second side.

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