Instrument shafts with release features and related devices, systems, and methods

Abstract

Instrument shafts with release features and related devices, systems, and methods. An instrument includes a tubular shaft, an end effector coupled to a distal end portion of the tubular shaft, and a release feature extending circumferentially along a wall of the shaft and along at least a portion of a length of the shaft. The release feature defines flexible members on opposite sides of the release feature. The flexible members may move relative to each other in response to bending of the shaft. The flexible members may engage each other on one or both of the tension side and the compression side of the shaft in a condition where the shaft is bent to an angle within a predetermined range of bending angles. Systems and methods relate to instruments including such shafts.

Description

[0001] This application is a divisional application of Chinese Patent Application 2020800920553 (PCT / US2020 / 064538), filed on December 11, 2020, entitled "A device shaft with a release feature and related apparatus, system and method".

[0002] Cross-references to related applications This application claims priority to U.S. Provisional Application No. 62 / 947,079 (filed December 12, 2019), entitled “INSTRUMENT SHAFTS WITH RELIEF FEATURES, AND RELATEDDEVICES, SYSTEMS, AND METHODS”, the entire contents of which are incorporated herein by reference. Technical Field

[0003] This disclosure relates to an instrument shaft having a relief feature that increases shaft flexibility without increasing backlash, and related systems and methods. Background Technology

[0004] Instruments, such as surgical or industrial devices, can be configured in various ways to perform a wide range of procedures. Some instrument systems are configured for minimally invasive surgery. In some such systems, each individual instrument includes an end effector at the distal end of an axis for positioning at the location where the procedure will take place. Such instruments may include a drive mechanism positioned proximally on the axis and configured to mount the instrument to a manipulator system (such as a remotely operated (e.g., computer-controlled) manipulator system, or a manipulator system configured for manual operation). The drive mechanism of these tools may include a number of mechanical subsystems that receive mechanical input (e.g., from the manipulator system or manually received by the user) and generate movement and actuation of the instrument, such as operation of the end effector, articulation of one or more joints of the proximal axis of the end effector, axis rolling, and other operations or movements. Other instruments for medical, industrial, or other applications may include shafts and associated components with similar structures and functions.

[0005] For various reasons, a certain degree of flexibility may be desired for the shafts of such instruments. For example, in a system with multiple instruments configured to perform a program at a single location, as described above, the end effectors at the distal ends of the instrument shafts must be parallel and closely approximated. Because the associated drive mechanisms at the proximal ends of the shafts contain a potentially large number of mechanical components and subsystems, the dimensions of the drive mechanisms constrain how closely the proximal ends of the shafts can be positioned together. Allowing the shaft to have a certain degree of bending flexibility allows the distal ends to be closely approximated while allowing sufficient spacing in the drive mechanisms at the proximal ends. In other applications and system architectures, a certain degree of flexibility may be desired for other reasons. However, shafts made of flexible materials may behave undesirably in some applications, such as exhibiting higher axial compliance than expected.

[0006] There is a need to provide an instrument shaft that exhibits relatively high compliance with bending, as well as relatively high axial and rotational stiffness. Summary of the Invention

[0007] Exemplary embodiments of this disclosure can solve one or more of the problems described above and / or exhibit one or more of the desired features described above. Other features and / or advantages will become apparent from the following description.

[0008] According to at least one exemplary aspect of this disclosure, an apparatus includes a tubular shaft, an end effector coupled to a distal portion of the tubular shaft, and a release feature extending circumferentially along a wall of the shaft and along at least a portion of the shaft's length, the release feature defining flexible members on opposite sides of the release feature. The flexible members move relative to each other in response to bending of the shaft. When the shaft bends to an angle within a predetermined range of bending angles, the flexible members engage with each other on one or both of the tension and compression sides of the shaft.

[0009] According to at least another exemplary aspect of this disclosure, a method of mounting an instrument to a manipulator system includes bending the shaft of the instrument to an angle within a predetermined range of bending angles. During bending, flexible members defined by release features in the walls of the shaft move relative to each other, and when the shaft is bent to an angle within the predetermined range of bending angles, the flexible members engage with each other on one or both of the tension side and the compression side of the shaft.

[0010] According to another exemplary aspect of this disclosure, a method of manufacturing an instrument shaft includes forming a release feature along the wall of a tubular shaft. The release feature defines a flexible member on opposite sides of the release feature of the tubular shaft body. When the shaft is bent to an angle within a predetermined range of bending angles, the flexible member is configured to engage with each other on one or both of the tension and compression sides of the shaft.

[0011] According to another exemplary aspect of this disclosure, an apparatus includes a tubular shaft and an end effector coupled to a distal portion of the tubular shaft. A release feature extends circumferentially along a wall of the shaft and along at least a portion of the shaft's length. The release feature defines flexible members on opposite sides of the release feature. When the shaft bends to an angle below a predetermined range of bend angles, the flexible members are movable relative to each other. When the shaft bends to an angle within a predetermined plurality of bend angles, the flexible members engage with each other and prevent one or both of torsional and axial movement of the flexible members relative to each other.

[0012] Additional objects, features, and / or advantages will be set forth in part in the description which follows, and will be apparent in part from the description, or may be learned by practice of the present disclosure and / or the embodiments. At least some of these objects and advantages may be realized and obtained by means of the elements and combinations particularly pointed out in the embodiments.

[0013] It should be understood that the foregoing general description and the following detailed description are merely exemplary and explanatory. Attached Figure Description

[0014] This disclosure can be understood from the following detailed description, either alone or in conjunction with the accompanying drawings. The drawings are included to provide a further understanding of this disclosure and are incorporated into and constitute a part of this specification. The drawings illustrate one or more exemplary embodiments of the teachings and, together with the description, explain certain principles and operations. In the drawings, Figure 1 This is a partial schematic diagram of an embodiment of the control arm of a computer-assisted surgical system, in which two instruments are in the loading position.

[0015] Figure 2 This is a schematic diagram of an exemplary embodiment of a device according to embodiments of the present disclosure.

[0016] Figure 3 This is a side view of the instrument axis according to an exemplary embodiment of the present disclosure.

[0017] Figure 4 yes Figure 3 A magnified view of a portion of the instrument's axis.

[0018] Figure 5A This indicates a neutral configuration. Figure 4 A partially enlarged side view of the release feature of the instrument shaft.

[0019] Figure 5B This indicates that it is in a stretched configuration. Figure 4 A partially enlarged side view of the release feature of the instrument shaft.

[0020] Figure 5C This indicates that it is in a compressed configuration. Figure 4 A partially enlarged side view of the release feature of the instrument shaft.

[0021] Figure 6A This is a partially enlarged side view of an instrument shaft with a release feature in a neutral configuration, according to another exemplary embodiment of this disclosure.

[0022] Figure 6B The release feature is in a compressed configuration. Figure 6A A partially enlarged side view of the instrument's axis.

[0023] Figure 6C The release feature is in a stretched configuration. Figure 6A A partially enlarged side view of the instrument's axis.

[0024] Figure 7 This is a partially enlarged side view of a release feature according to another exemplary embodiment of the present disclosure.

[0025] Figure 8 This is a partially enlarged side view of a release feature according to another exemplary embodiment of the present disclosure.

[0026] Figure 9 This is a partially enlarged side view of a release feature according to another exemplary embodiment of the present disclosure.

[0027] Figure 10A This is a side view of the device in its unpositioned state according to this disclosure.

[0028] Figure 10B yes Figure 10A Front view of the instrument.

[0029] Figure 10C It is in the loading and positioning stage. Figure 10A and Figure 10B A side view of the instrument.

[0030] Figure 10D yes Figure 10C A front view of the instrument in its loading and positioning position.

[0031] Figure 11 This is a partially enlarged side view of a release feature according to another exemplary embodiment of the present disclosure.

[0032] Figure 12A This is a partially enlarged side view of a shaft having a release feature according to another exemplary embodiment of the present disclosure.

[0033] Figure 12B Under axial compressive load Figure 12A A partially enlarged side view of the axis.

[0034] Figure 12C Under bending load Figure 12A Side view of the axis. Detailed Implementation

[0035] This disclosure contemplates various exemplary embodiments of shafts for instruments, including release features that impart lateral flexibility (bending) to the shaft while maintaining relatively high axial stiffness and minimizing (e.g., reducing or eliminating) rotational backlash to allow controlled rolling of the shaft. Such shafts can be made of relatively rigid materials, such as metal alloys, polymers, or other materials, to provide the required stiffness and durability under the specific conditions of instrument use, while the release features impart flexibility to allow a degree of bending. For example, in one use case, such a shaft can facilitate coupling an instrument to a manipulator in a usage configuration. Such shafts can be used in any other situation requiring a degree of shaft flexibility.

[0036] In one embodiment of this disclosure, the shaft includes a release feature that extends circumferentially around at least a portion of the shaft and at least partially through the shaft's wall thickness, thereby defining an adjacent portion of the shaft. The release feature defines complementary interlocking engagement members that engage with each other at different locations depending on whether the complementary interlocking engagement members are located on the tension or compression side of the shaft when the shaft having the release feature bends to a predetermined angle. The engagement between the complementary interlocking engagement members at the predetermined bending angle minimizes (e.g., reduces or eliminates) rotational backlash in the shaft (e.g., movement of a portion of the shaft relative to other portions of the shaft due to torsion about the shaft's longitudinal axis) and ensures that the shaft maintains axial and rotational stiffness upon reaching the predetermined bending angle.

[0037] A shaft with such a release feature can facilitate the desired positioning of associated instruments, for example, in conjunction with... Figure 1 In the multi-instrument configuration discussed above and below. Furthermore, the release feature provides the desired degree of flexural flexibility for such use, while maintaining rotational and axial compliance at a level approximately equal to the properties exhibited by the shaft material. Therefore, a shaft with a release feature according to embodiments of this disclosure is able to withstand reaction forces generated by actions such as actuation of an end effector coupled to the shaft, rotation of the shaft in rolling motion, or other movements, with reduced deflection compared to conventional shafts exhibiting a similar degree of flexibility.

[0038] In the following description, shafts according to exemplary embodiments of the present disclosure are disclosed and described in conjunction with a manipulator system having multiple instruments. However, shafts having the features disclosed herein can be used in any application where the flexibility of the shaft is desired to position the shaft without significantly compromising the axial and rotational stiffness of the shaft.

[0039] Now for reference Figure 1A schematic diagram of a manipulator system 100 including a manipulator arm 103 is shown, with two surgical instruments 104, 106 in a loaded position. The surgical instruments 104, 106 can generally correspond to instruments discussed below, such as combined... Figure 2 The disclosed device 204. For example, the embodiments described herein can be used with the DA VINCI SP® surgical system, commercially available from Intuitive Surgical, Inc., Sunnyvale, California. For simplicity, Figure 1 The schematic diagram depicts only two surgical instruments, but as those skilled in the art will recognize, more than two surgical instruments can be mounted in the loading position at the control system. Each of surgical instruments 104 and 106 includes instrument axes 105 and 107, respectively, with a movable end effector or endoscope, camera, or other imaging or sensing device at its distal end, and may include or exclude a wrist mechanism (not shown) to control the movement of the distal end.

[0040] exist Figure 1 In this embodiment, the distal portions of surgical instruments 104, 106 are received via a single port structure 108 for introduction into the patient. As shown, the port structure includes a cannula 110 and an instrument access guide 112 inserted into the cannula 110. Individual surgical instruments 104, 106 are inserted into the guide 112 and reach the surgical site via the cannula 110.

[0041] Transmission mechanisms 114 and 116 (which can usually correspond to the coupling) Figure 1 The disclosed force transmission mechanism 102 is disposed at the proximal end of each instrument shaft 105, 107 and connected to the drive assemblies 122, 124 via sterile adapters 118, 120. The drive assemblies 122, 124 contain various internal mechanisms (not shown) controlled by a controller (e.g., at the control interface of the manipulator system) to transmit force to the transmission mechanisms 114, 116 in response to input commands at the user control system of the manipulator system 100 to actuate the surgical instruments 104, 106.

[0042] like Figure 1 As shown, as the instrument shafts 105 and 107 enter the entry guide 112, they are positioned close to each other and gradually diverge from each other in the proximal direction (i.e., toward the transmission mechanisms 114 and 116 and the drive assemblies 122 and 124). Due to this divergence, each of the instrument shafts 105 and 107 exhibits a slight S-shaped bend, as discussed in more detail below.

[0043] In some exemplary embodiments of this disclosure, when the instrument is in the loading position in the manipulator system 100, the instrument shafts 105, 107 may exhibit one or more complex bends. Furthermore, the instrument shafts 105, 107 may exhibit simple or complex bends in one or more different bending planes. For example, referring now... Figures 10A to 10D Various views of the device 1104 are shown. Figure 10A and Figure 10C This is a side view of instrument 1104 (similar to...) Figure 2 (View of instrument 204) Figure 10B and Figure 10D This is an end view of instrument 1104 (similar to...) Figure 1 (Views of instruments 104 and 106 in the diagram). Figure 10A and Figure 10B This indicates that the device 1104 is in an unloaded state according to this disclosure. In this embodiment, the shaft 1105 of the device 1104 extends from the transmission mechanism 1114 at a non-orthogonal angle θ. Figure 10A and Figure 10B As shown, in its unpositioned state, shaft 1105 typically extends directly from transmission mechanism 1114. Figure 10C As can be seen from the image, shaft 1105 exhibits a gradual arc-shaped bend B during installation and positioning, as if the shaft is placed... Figure 10C In the plane. Axis 1105 is in Figure 10D The plane exhibits a complex bending C. Figure 10D The compound bending of shaft 1105 shown in the figure causes multiple instruments (e.g.) to bend. Figure 1 The devices 104 and 106 in the middle can be mounted parallel to each other and compensate for the transmission mechanism 1114 and the entry guide ( Figure 2 The required offset between ) to enable multiple instruments (e.g., Figure 2 Instruments 104 and 106 are inserted through the same entry guide (e.g., Figure 2 (Entry guide 112 in the middle). Other combinations of simple and / or complex bends in one or more bending planes are within the scope of this disclosure. Embodiments of this disclosure provide shafts with features that facilitate the presentation of desired bending geometry while maintaining the desired level of axial and rotational stiffness in the shaft.

[0044] The embodiments described herein are not limited to Figure 1The embodiments described herein are examples, and various other remotely operated, computer-aided manipulator configurations can be used in conjunction with the embodiments described herein. The diameters of the instrument axis, wrist mechanism, and end effector are typically selected based on the size of the cannula from which the instrument will be used and depending on the surgical procedure being performed. Other configurations of the manipulator system that can be used in conjunction with this disclosure may use a plurality of separate manipulator arms. Furthermore, a single manipulator arm may comprise a single instrument or multiple instruments. In addition, as discussed above, the instrument may be a surgical instrument with an end effector, or it may be a camera instrument or other sensing instrument used during a surgical procedure to provide information about the surgical site remotely (e.g., visualization, electrophysiological activity, pressure, fluid flow, and / or other sensing data).

[0045] Now for reference Figure 2 A schematic side view of an embodiment of instrument 204 (e.g., surgical instrument 104 or 106) is shown. Although aspects of this disclosure are discussed in the context of surgical instruments, embodiments of this disclosure can be used with a variety of instruments used in surgical or non-surgical procedures. For example, such instruments include those for diagnostic, therapeutic, and sensing purposes, including, for example, imaging instruments (such as endoscopes) and other imaging devices. Thus, surgical instruments as used herein encompass a wide range of instruments used in surgical, diagnostic, and therapeutic applications. Furthermore, aspects of this disclosure can have non-surgical applications, such as in other remotely actuated instruments for inspection and other industrial uses, general robotic uses, manipulation of non-tissue workpieces, etc.

[0046] The device 204 includes a transmission mechanism 214 at the proximal end of the shaft 205. In an exemplary embodiment, the transmission mechanism 214 is configured to interact with an actuation system (e.g., in conjunction with...). Figure 1 The manipulator 100 discussed is docked. Alternatively, the transmission mechanism 214 can be configured for manual operation, for example, for manual laparoscopic instruments.

[0047] The end effector 226 is coupled to the distal portion of the shaft 205. The end effector 226 may be directly coupled to the shaft 205 or may be coupled to the shaft 205 via a wrist 228, which may include one or more articulated joints to give the end effector 226 one or more degrees of freedom of movement relative to the shaft 205 (e.g., moving the wrist 228 in one or more of pitch and yaw).

[0048] The end effector 226 can be operated manually or by manipulating a system (e.g., Figure 1The control system 100 shown uses a drive element to manipulate the transmission mechanism 214 for control. The transmission mechanism 214 includes various mechanical and / or electromechanical devices that transmit motion, energy, and / or signals from the control system or from inputs at the user-operable transmission mechanism 214 to the end effector 226. Although Figure 2 The end effector 226 shown includes a pair of opposing jaw members, but other end effector configurations (such as suture devices, clamps, ligation tools, and other tools) are considered to be within the scope of this disclosure.

[0049] As described above, the device 204 may also include a wrist 228 to facilitate orientation of the end effector 226. For example, the wrist 228 may include one or more articulated joints disposed at the distal portion of the shaft 205 and couple the end effector 226 to the shaft 205 such that the end effector 226 moves relative to the shaft 205 in one or more degrees of freedom.

[0050] Now for reference Figure 3 The image illustrates an instrument shaft 305 according to an embodiment of the present disclosure. The instrument shaft 305 includes a tubular structure comprising one or more portions having release features that impart flexibility to the shaft 305 while minimizing (e.g., reducing or eliminating) a corresponding increase in axial or rotational compliance. As used herein, the terms "tubular," "tube," and variations thereof refer to a structure having lateral walls defining an internal hollow portion. The cross-sectional shape of the lateral walls (i.e., the shape in a plane orthogonal to the longitudinal axis) is not limited and can be, for example, circular, oval, elliptical, polygonal, combinations thereof, or any other shape. Furthermore, the cross-sectional shape of the lateral walls can be constant along the length of the shaft or can vary along the length of the shaft. When the shaft 305 and the corresponding instrument are loaded into an actuator system (e.g., combined with…) Figure 1 In the discussed manipulator system 100, one or more parts can be positioned along axis 305 in a configuration that allows axis 305 to exhibit a slight S-shaped bend (e.g., Figure 1 (as shown in the image) at the location.

[0051] For example, in Figure 3 In one embodiment, shaft 305 includes a first portion 330 and a second portion 332, each of the first and second portions having a feature (e.g., a release feature) configured to impart flexibility to shaft 305. Figure 3The longitudinal positioning of the first portion 330 and the second portion 332 shown is merely exemplary, and such portions can be located anywhere along the length of axis 305. Additionally, axis 305 may optionally include only one portion with the release feature, or three or more portions. The number of portions, the longitudinal extent of the portions, and the location of the portions with the release features can be selected based on the total deflection required for the specific configuration of the surgical instrument and manipulator system. For example, if a relatively large amount of deflection is required, a larger number and / or a larger longitudinal extent (i.e., length) of portions can be utilized. In some embodiments, axis 305 may optionally include a release feature along most of its length.

[0052] The release feature may include a release element formed by the wall thickness of a tubular structure passing through the shaft 305. For example, the release feature may include a negative feature formed by a thickness that completely passes through the shaft wall thickness. In some exemplary embodiments, such a negative feature may extend approximately around the circumference of the shaft 305 and may have a generally helical pattern, such that the shaft remains a single workpiece. In other exemplary embodiments, the negative feature may extend circumferentially and separate the shaft 305 into discrete but interlocking workpieces. The release feature may have a configuration that minimizes (e.g., reduces or eliminates) the axial and rotational compliance of the shaft when the shaft is in a bent position, such as in combination with Figure 4 and Figures 5A to 5C To be discussed in more detail.

[0053] Now for reference Figure 4 An enlarged view is shown of a portion (e.g., portion 330 or 332) of the shaft 405 having the release feature 434. Figure 4 As shown, the release feature 434 extends through the wall of the shaft 405 and extends in a generally spiral pattern around the circumference of the shaft. The release feature 434 defines opposite sides 435 and 436 of the shaft 405. Figure 4 In one embodiment, opposite sides 435 and 436 represent adjacent helical windings of shaft 405, and therefore opposite sides 435 and 436 can be different portions of the same single component (i.e., shaft 405), since shaft 405 remains a single workpiece due to the helical formation of release feature 434. In other embodiments, for example, where release feature 434 is formed as a series of concentric non-helical release elements, opposite sides 435 and 436 can be completely separate components. Furthermore, reference can be made to the release features (e.g., release features 434, 634 (FIG. 6), 834 (FIG. 7), etc.) as discussed herein. Figure 8 ), 934 Figure 9 ) and 1134 ( Figure 11 The multiple parts 434 of the separate shaft 405 can be called flexible members because the release feature 434 can give the shaft 405 additional flexibility.

[0054] The release feature also defines an interlocking feature configured to minimize (e.g., reduce or eliminate) the axial and rotational compliance (e.g., rotational backlash) introduced by the release feature 434. For example, such a feature could be configured to mechanically interlock to impart axial and rotational stiffness to the shaft 405 when it bends to a predetermined angle. Figure 4 As shown, the release feature 434 defines a repeating interlocking pattern in the shaft 405 with the complementary interlocking engagement member 438. When the shaft is subjected to rotational torque, the interlocking feature is used to prevent rotational compliance (e.g., backlash caused by multiple parts of the shaft moving relative to other parts of the shaft due to torsion of the shaft about the longitudinal axis).

[0055] Now for reference Figure 5A An enlarged view of the release feature 434 is shown. (See attached image.) Figure 5A As shown in the embodiment, the release feature 434 defines opposite sides 535 and 536 of the shaft, each side of the shaft (e.g., Figure 4 The shaft 405 has a complementary interlocking engagement member 538. For example... Figure 5A As shown, each of the complementary interlocking joint members 538 has a width of W. B The base is 540, and the width is W. N The neck is 542 and the width is W. H The head is 544. The width W of the base is 540. B and the width W of the head 544 H Width W greater than 542 mm of the neck N Each of the complementary interlocking joint members includes a corresponding feature, and as shown in the figure. Figure 5A As shown, the complementary interlocking joint members are configured such that they form interlocking components separated by gap 546. Gap 546 may be the result of a manufacturing process, such as a cut left by a cutting process (e.g., laser cutting, waterjet cutting, milling or other machining processes or other processes), and may have a constant width or may have a varying width as described in more detail below.

[0056] Width W of head 544 and base 540 H and W B In comparison, the neck has a relatively narrow width W. N The longitudinal axis A is defined relative to axis 305. L ( Figure 3 The angled portions 548 and 550 are oriented at an acute angle. Now refer to... Figure 5B This shows a view of the complementary interlocking engagement member 538 in an interlocking engagement. This condition occurs when shaft 305 bends to a predetermined bending angle. Figure 3 The stretching side is associated with (e.g.) Figure 5BAs shown, the angled portions 548 and 550 of the complementary interlocking joint members interlock with each other and prevent the opposite sides 535 and 536 from interlocking along axis 305. Figure 3 The longitudinal axis A L Any further relative axial movement.

[0057] Now for reference Figure 5C This illustrates that when shaft 305 is bent to a predetermined angle, the complementary interlocking engagement member 538 is in contact with shaft 305 ( Figure 3 A view of the engagement condition associated with the compression side of the image. (e.g.) Figure 5C As shown, each head 544 contacts the opposite sides (i.e., opposite sides 535 and 536) between adjacent bases 540, thereby preventing the opposite sides 535 and 536 from spreading along the longitudinal axis A of axis 305. L Further relative axial movement.

[0058] like Figure 5B and Figure 5C As shown, the configuration of the release feature 434 allows relative movement between the complementary interlocking engagement members 538 within an angular range up to a predetermined bending angle, thereby reinforcing the shaft 305 ( Figure 3 ) Flexibility within an angle range up to a predetermined bending angle. For example... Figure 5B and Figure 5C As shown, once a predetermined bending angle is reached, the contact between the complementary interlocking engagement members 538 on the compression and tension sides of the shaft prevents further movement, such that the axial stiffness exhibited by the shaft portion including the release feature is approximately equal to the axial stiffness of the shaft portion excluding the release feature. In some embodiments, the predetermined bending angle corresponds to the bending angle obtained by the shaft when the instrument is installed in the manipulator system, for example in Figure 1 In the configuration of instruments 104, 106 and manipulator 100. For example, such bending angles can be in the range of up to 10 degrees, up to 20 degrees, or other ranges. In one exemplary embodiment, the bending angle required to insert the shaft into the manipulator is approximately 5 degrees.

[0059] Furthermore, the predetermined bending angle can include a range of predetermined bending angles for the shaft. For example, various factors such as variations in manufacturing tolerances and material properties may cause complementary interlocking members to engage at slightly different bending angles, depending on the rotational orientation and the external forces applied to the shaft. Therefore, although the shafts of this disclosure are described as engaging at predetermined angles, those skilled in the art will understand that such predetermined angles are subject to normal variation, and the predetermined angles discussed herein are therefore subject to variations caused by these factors.

[0060] In addition to providing the axial stiffness described above, the release feature can also be configured to exhibit rotational stiffness approximately equal to that of the shaft portion excluding the release feature. For example, when the shaft bends to a predetermined bending angle, the complementary interlocking engagement features defined by the release feature can be configured to engage with each other to prevent rotational movement between the complementary interlocking engagement features.

[0061] For example, such as Figure 5C As shown, the angled portions 551 and 553 are on axis 305 ( Figure 3 The compression sides of the parts 551 and 553 engage with each other. To ensure that the angled portions 551 and 553 engage on both sides of the complementary interlocking engagement feature, the gap 546 ( Figure 5A The width of the face 552 along the head 544 is wider than the width of the gap 546 along the angled portions 550 and 548. The size of the gap 546 along the head 544 relative to the gaps along the angled portions 548, 550, 551, and 553 can be determined by the angle formed between the angled portion 550 and the gap along the face 552. For example, in Figures 5A to 5C In this embodiment, the angled portions 551, 553 are formed at a 45-degree angle relative to the other portions of the gap 546. To ensure that the angled portions 551 and 553 fully engage with each other, the size of the gap 546 along the surface 552 is equal to the gap 546 between the angled portions 551, 553 divided by the cosine of the 45-degree angle. As a non-limiting example, if the gap 546 between the angled portions 550 is 0.001" (0.0254 mm), then the gap between the non-angled portions is 0.001" / cos(45°) = 0.0014" (0.036 mm). The additional gap width in the non-angled portions ensures that the angled portions 550 fully engage with each other when a predetermined bending angle is reached to reduce or prevent relative rotation between the opposite sides 535 and 536.

[0062] The angles subtended by the angled portions relative to the non-angled portions are foreseeable, and therefore other relative differences between the gaps between the angled portions and the gaps between the non-angled portions are also within the scope of this disclosure. Furthermore, if the gap 546 along surface 552 is made even larger than the gap 546 between the angled portions 551 and 553 divided by the cosine of that angle, then surface 552 will not “bottom out” between the heads 544, but the angled portions 551 and 553 will engage with each other and will prevent rotation and axial relative movement between the opposite sides 535 and 536.

[0063] In other embodiments, the width of the gap 546 may optionally be consistent throughout the release feature. In such embodiments, and when the pattern of the release feature is otherwise substantially similar... Figures 5A to 5C In this configuration, the end of the head 544 contacts the shaft between adjacent bases before the angled portions 550 contact each other, thus allowing a degree of rotational compliance even when a predetermined bending angle is reached. However, in some applications, the rotational compliance introduced by the equal-width clearance may be small enough not to significantly impair the function of the shaft and associated instruments. Furthermore, the equal-width clearance may be less expensive to manufacture than the variable-width clearance described above, and is therefore economical for applications where a small amount of rotational compliance is acceptable.

[0064] Now for reference Figure 6A This illustrates another embodiment of a shaft 605 having a release feature 634 according to the present disclosure. Similar to... Figures 5A to 5C In one embodiment, the release feature 634 is configured to prevent rotational movement (e.g., torsional movement) of opposite sides 635 and 636 relative to each other when the shaft 605 bends to a predetermined bending angle. Figure 6A As shown, release feature 634 defines a generally rhomboid complementary interlocking engagement member 638. Release feature 634 defines a forward-angled portion 648 on each of the complementary interlocking engagement members 638, which, as discussed in more detail below, contacts corresponding portions on opposite sides 635 and 636 when the shaft 605 bends to a predetermined angle. Figures 4 to 5C Unlike the embodiment shown, the release feature 634 does not include any portion extending in a plane orthogonal to the longitudinal axis of axis 605, and the gap 646 defining the release feature 634 has a uniform width throughout the release feature 634.

[0065] Figure 6B A complementary interlocking engagement member 638 is shown in an engagement state associated with the compression side of shaft 605 when shaft 605 is bent to a predetermined angle. This is relative to the longitudinal axis of shaft 605 (e.g., Figure 3 The axis A shown L The angled portions 651 and 653, forming a non-orthogonal angle, engage as the opposing sides 635 and 636 come together, thereby preventing relative rotation between the opposing sides 635 and 636 on the compression side of shaft 605. Similarly, now referring to... Figure 6C On the tension side of shaft 605, angled portions 648 and 650 of complementary interlocking members 638 on opposite sides 635 and 636 of shaft 605 engage with each other to prevent relative rotation of opposite sides 635 and 636 once shaft 605 reaches a predetermined bending angle, similar to that discussed above. Figures 4 to 5C Examples of implementations.

[0066] To ensure that the angled portions 651 and 653 fully engage with each other on the compression side of the shaft 605 when the shaft 605 is bent to a predetermined angle, the release feature 634 may be included in the release area where the angled portions 651 and 653 become together. Figure 7 The illustration provides why, in the absence of such a release area, the angled portions 751 and 753 may not fully engage with each other to prevent backlash in the shaft's rotation. The equal configuration of the gap 646 throughout the release feature 634 will result in point or near-point contact at the contact area 754, as... Figure 7 As shown, the angled portions 751 and 753 are still separated by a gap. This configuration results in rotational backlash when the shaft rotates.

[0067] Now for reference Figure 8 An exemplary embodiment is shown in which the release feature 834 is provided with a release region 854. Figure 8 In one embodiment, the release feature 834 includes a release region 856 that provides space between the tips 858 of the complementary interlocking engagement feature 838 and the angled portions 848, such that the angled portions 851 and 853 can be... Figure 8 The engagement shown prevents backlash when the interlocking engagement members are interlocked.

[0068] Figure 9 Another exemplary embodiment of the release feature 934 is shown. In this embodiment, the radius of the tip 958 of the complementary interlocking engagement feature 938 between the angled portions 951 and 953 is larger than the corresponding groove 960 of the receiving tip. Figure 9 As shown, this arrangement also allows the angled portions 951 and 953 to fully contact each other, thus preventing backlash in the shaft's rotation.

[0069] Figure 8 and Figure 9 The embodiments described are exemplary and non-limiting, and any configuration that enables the angled portions 651, 851, 951 and 653, 853 and 953 to fully contact is within the scope of this disclosure. Furthermore, as described above... Figures 3 to 5C As discussed in the embodiments, a certain degree of rotational compliance may be acceptable as a trade-off for reducing manufacturing costs. This can be achieved with a clearance of constant width, such as a laser-cutting tool or other tool used to form release features on the shaft. Therefore, although shown and described herein... Figure 7 Mainly to explain Figure 8 and Figure 9 The advantages provided by the embodiments, but Figure 7 The embodiments described above can also be used where such a degree of rotational compliance is acceptable in exchange for lower manufacturing costs.

[0070] In addition, Figure 7 Under sufficient axial load, plastic deformation of the tip of the shaft portion at contact region 754 can optionally be induced in the embodiment until the angled portions 751 and 753 contact each other. After such plastic deformation occurs, the angled portions 751 and 753 function similarly to the combination described above. Figure 8 and Figure 9 The angled portions 851, 853 and 951, 953 discussed herein, wherein angled portions 751 and 753 engage with each other on the compression side of the bent shaft to reduce (e.g., eliminate) rotational backlash in the shaft. In this way, i.e., by making Figure 7 The shaft is subjected to axial loads sufficient to cause plastic deformation of the tip portion. The manufacturing cost savings of the equal-width release can be achieved together with the backlash prevention provided by other designs, including releases with different widths.

[0071] In a roughly similar manner to combination Figures 3 to 5C In embodiments described herein, a certain degree of rotational backlash may exist in the shaft, particularly in portions where the shaft bends to an angle smaller than a predetermined bending angle and results in an angular portion (e.g., Figures 5A to 5C The angled portions 548, 550, 551, and 553 of the shaft do not fully engage with each other on the tension and compression sides. This backlash can be a result of a release feature that extends in a continuous helical pattern around the shaft. Therefore, some exemplary embodiments may include a release feature configured to reduce (e.g., eliminate) backlash at any degree of curvature from zero degrees to a predetermined curvature angle.

[0072] Now for reference Figure 11 Another embodiment of a shaft 1105 with a release feature 1134 is shown. The shaft 1105 is shown as a 180° portion of the circumference of the shaft projected onto… Figure 11 In the plane. The release feature 1134 includes a plurality of unconnected release elements 1162 extending around the entire circumference of the smaller axis 1105. Figure 11 As shown, multiple unconnected release elements 1162 extend in a non-helical direction, which is located on the longitudinal axis A orthogonal to axis 1105. L In the plane. Because no individual unconnected release element 1162 extends completely around the circumference of the shaft 1105, the unconnected release elements 1162 do not introduce rotational backlash in the shaft. The material of the shaft 1105 retained between the individual unconnected release elements 1162 can form a flexible member 1163 that elastically deforms as the shaft 1105 bends. Although Figure 11In the embodiments described, the unconnected release member 1162 is not helically extended, but in other exemplary embodiments, the unconnected release member may extend about the axis 1105 in a helically pattern and / or other patterns. Furthermore, although Figure 11 The projection represents the 180° portion of the circumference of axis 1105, but with Figure 11 Compared to the embodiments shown, each of the unconnected release members 1162 may extend less or more around the axis 1105.

[0073] As shaft 1105 bends to a desired angle, such as the predetermined bending angle discussed above in conjunction with various other embodiments, the portion of shaft 1105 defined by the unconnected release member 1162 (e.g., flexible member 1163) can undergo elastic deformation and thus facilitate bending of shaft 1105 to the desired angle. Further bending of shaft 1105 can potentially lead to plastic deformation of shaft 1105 or otherwise damage to the structure and materials of shaft 1105. To prevent bending of shaft 1105 beyond the bending permissible by the elastic deformation of the shaft portion defined by the unconnected release member 1162, release feature 1134 may include engagement member 1139 mating within recess 1141 to prevent bending of shaft 1105 beyond the predetermined bending angle. Engagement member 1139 and the corresponding recess 1141 function similarly to the above-described combination. Figures 3 to 5C The interlocking engagement members 438, 538, and 638 discussed in the embodiments prevent the shaft 1105 from bending beyond the predetermined bending angle by engaging at a predetermined bending angle.

[0074] exist Figure 11 In one embodiment, the release feature includes two rows of longitudinally engaged members 1139, which are radially opposed to each other about the shaft 1105. To increase (e.g., maximize) the axial stiffness of the shaft 1105 in use, the shaft 1105 can be oriented such that when a row of engaged members 1139 is positioned on the compression side of the shaft 1105, the base 1164 of each engaged member 1139 contacts a corresponding base 1166 of each recess 1141 of the release feature 1134. Similarly, the angled portion 1168 of each engaged member 1139 can be configured to contact the angled portion 1170 of each recess 1141 on the tension side of the shaft 1105 to contribute axial stiffness to the shaft 1105 when it bends to a predetermined bending angle.

[0075] Now for reference Figure 12A This illustrates another exemplary embodiment of a shaft 1205 with a release pattern according to the present disclosure. Figure 12A In one embodiment, the release feature includes an unconnected radially cut release member 1274 that extends partially around the axis 1205. The radially cut release member 1274 is arranged in a repeating, offset pattern along a portion of the axis 1205. Figure 12A In the example, release element 1274 is repeated four times around the circumference of shaft 1205. Other embodiments may include fewer or more release elements around a perimeter (e.g., a circumference), and the number of release elements around a perimeter (e.g., a circumference) may be varied along with other variables (e.g., the length and width of the release elements, the spacing along the axis of shaft 1205), and the total number of rows of release elements may be selected based on the desired characteristics of the shaft.

[0076] Similar to Figure 11 In an exemplary embodiment, the material retained between the release members 1274 forms a flexible member 1263 that is elastically deformable to allow the shaft 1205 to elastically bend to the desired degree. Furthermore, because the flexible members 1263 are coupled to each other in a continuous manner, the shaft 1205 is able to transmit the applied torque without excessive mechanical backlash.

[0077] Now for reference Figure 12B , Figure 12A A side view of shaft 1205 is shown in an axially compressed state. Under sufficient axial compressive load, the central portions of the flexible members 1263 deflect (e.g., move relative to each other) in the axial direction of shaft 1205 until they contact each other. Once sufficient axial load occurs to engage the flexible members 1263 with each other, the mechanical contact (e.g., engagement) between the flexible members 1263 contributes to the axial stiffness of shaft 1205.

[0078] Now for reference Figure 12C , Figure 12A and Figure 12B The side view of shaft 1205 is shown as being in a bent state. Figure 12C In the configuration, the left side of shaft 1205 (e.g.) Figure 12C The shaft 1205 is compressed on the right side, while the right side is stretched. On the left side, the flexible members 1263 are in contact due to compressive force, while on the right side, the flexible members 1263 are further separated by tensile force. In this condition, the contact of the flexible members 1263 on the compressed side of the shaft contributes to the relatively high axial stiffness of the shaft 1205. Because Figures 12A to 12C The embodiments described herein do not use interlocking features similar to those in other embodiments disclosed herein, so the resistance of shaft 1205 to plastic deformation in tension, compression, and / or torsion is limited by the material properties of shaft 1205, such as its elastic modulus, tensile strength, and compressive strength. Similarly, while shaft 1205 may be less susceptible to mechanical backlash due to the continuous nature of the flexible member 1263, elastic and / or plastic deformation of shaft 1205 in torsion can potentially occur depending on the magnitude of the applied load.

[0079] The release feature according to this disclosure offers various additional advantages. For example, many surgical instruments undergo autoclaving to clean and sterilize them for reuse. The high temperatures experienced by the instruments cause thermal expansion of components such as shafts, which in turn creates undesirable tension in components extending through the shaft (e.g., tension cables or rods for actuating wrists or end effectors). Surgical instrument shafts with the release feature according to this disclosure can exhibit a shorter overall length than corresponding shafts without the release feature when not bent to a predetermined maximum angle, because in a straight configuration, the release feature of the shaft also contracts around the circumference of the shaft, thereby reducing the shaft length from its effective "in-use" length. Furthermore, some instruments with conventional shafts require additional mechanisms to release tension on the actuating elements when the instrument is removed from its associated manipulator, and the instrument shaft of this disclosure eliminates the need for such mechanisms, thereby reducing the weight, cost, and complexity of the instrument.

[0080] The instruments included in the embodiments described herein can be used with, for example, remotely operated computer-assisted surgical systems employing robotic technology, such as the DA VINCI® Surgical System (e.g., the DA VINCISI® Surgical System or DA VINCI XI® Surgical System, Da Vinci SP, and Ion, with or without Single-Site® single-port surgical technology, all commercialized by Intuitive Surgical, Inc., Sunnyvale, California). While the various embodiments described herein are discussed with regard to surgical instruments used with the manipulation systems of computer-assisted surgical systems employing robotic technology, this disclosure is not limited to use with surgical instruments intended for such surgical systems. For example, the various embodiments described herein can be optionally used in conjunction with handheld, manual, or semi-automatic surgical instruments, such as those for manual laparoscopic surgery, or other surgical and non-surgical instruments.

[0081] The accompanying drawings, which describe and illustrate exemplary embodiments, should not be considered limiting. Various mechanical, compositional, structural, electrical, and operational changes, including equivalents, may be made without departing from the scope of this specification and the claimed invention. In some cases, well-known structures and techniques have not been shown or described in detail so as not to obscure this disclosure. Identical reference numerals in two or more drawings denote identical or similar elements. Furthermore, elements and their associated features described in detail with reference to one embodiment may be included in other embodiments, where feasible, even if they are not specifically shown or described. For example, if an element is described in detail with reference to one embodiment but not with reference to a second embodiment, that element may still be claimed to be included in the second embodiment.

[0082] For the purposes of this specification, unless otherwise stated, all figures representing quantities, percentages, or proportions, as well as other numerical values ​​used in the specification, should be understood to be modified in all cases by the term "about," provided that they have not been so modified. Therefore, unless stated to the contrary, the numerical parameters set forth in the following specification are approximate values ​​that may vary depending on the desired characteristics sought to be obtained. At least, and not attempting to limit the application of the equivalence principle to the scope of the embodiments, each numerical parameter should be interpreted at least based on the number of significant figures reported and by applying common rounding techniques.

[0083] Note that, as used herein, the singular forms “a,” “an,” and “the,” and any singular use of any word, include plural indicators unless explicitly and unambiguously limited to one indicator. As used herein, the term “including” and its grammatical variations are intended to be non-restrictive, such that references to items in a list do not exclude other similar items that may be substituted for or added to the listed items.

[0084] Furthermore, the terminology used in this specification is not intended to limit the invention. For example, spatially related terms—such as “below,” “under,” “below,” “above,” “on top,” “near,” “far”, etc.—are used to describe the relationship of one element or feature to another element or feature shown in the figures. In addition to the positioning and orientation shown in the figures, these spatially related terms are intended to cover different positioning (i.e., location) and orientation (i.e., rotational placement) of the device in use or operation. For example, if the device in the figures is flipped, an element described as “below” or “below” other elements or features would be “above” or “on top” other elements or features. Thus, the exemplary term “below” can include both above and below positioning and orientation. The device may be oriented in other ways (rotated 90 degrees or in other orientations), and the spatially related descriptors used herein are interpreted accordingly.

[0085] Given the disclosure herein, further modifications and alternative embodiments will be apparent to those skilled in the art. For example, systems and methods may include additional components or steps omitted from the figures and descriptions for clarity of operation. Therefore, this description should be interpreted as illustrative only and for the purpose of teaching those skilled in the art the general manner of implementing this teaching. It should be understood that the various embodiments shown and described herein should be considered exemplary. Elements and materials, and arrangements of such elements and materials, may be substituted for those shown and described herein, parts and processes may be reversed, and certain features of this teaching may be used independently, all of which will be apparent to those skilled in the art after benefiting from the description herein. Changes may be made to the elements described herein without departing from the spirit and scope of this teaching.

[0086] It should be understood that the specific examples and embodiments described herein are non-limiting, and modifications can be made to the structure, dimensions, materials, and methods without departing from the scope of this teaching.

[0087] Other embodiments of this disclosure will be apparent to those skilled in the art upon consideration of the specification and practice of the invention disclosed herein. The specification and examples are intended to be illustrative only.

Claims

1. An apparatus comprising: tubular shaft; An end effector coupled to the distal portion of the tubular shaft; as well as A release feature extending circumferentially along the wall of the axis and along at least a portion of the length of the axis, the release feature defining a flexible member on opposite sides of the release feature; in: The flexible members move relative to each other in response to the bending of the shaft, and When the shaft bends to an angle within a predetermined range of bending angles, the flexible members engage with each other on one or both of the tension side and compression side of the shaft.

2. The device of claim 1, wherein the release feature extends in a generally helical pattern about at least a portion of the axis.

3. The device of claim 2, wherein the release feature extends in a spiral pattern along the wall of the axis.

4. The device according to claim 1, wherein the release feature comprises a plurality of release features spaced apart along the length of the axis.

5. The device of claim 1, wherein the release feature includes a gap between the flexible members when the shaft is in a straight configuration.

6. The device of claim 5, wherein the width of the gap varies along the release feature.

7. The device of claim 1, wherein each of the flexible members comprises a complementary interlocking engagement member, the complementary interlocking engagement member comprising a base portion having a first width, a neck portion having a second width, and a head portion having a third width.

8. The device according to claim 7, wherein the second width is smaller than the first width and the third width.

9. The device of claim 8, wherein each of the complementary interlocking engagement members includes an angled portion extending between the base portion and the neck portion.

10. The apparatus of claim 9, wherein the angled portion is located in a plane that is not orthogonally oriented to the longitudinal axis of the axis.

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