Drive mechanism for a surgical instrument used, for example, in a robotic surgical system

Abstract

A gear box assembly for use with a surgical instrument includes a drive gear configured to receive a rotational input, a first output gear configured to receive a rotational input from the drive gear, and a second output gear configured to receive a rotational input from the first output gear. The first output gear includes a first lead screw coupled to the first output gear such that a rotational input received by the first output gear causes the first lead screw to rotate and, in turn, causes a first nut threadingly engaged around the first lead screw to translate along the first lead screw. The second output gear includes a second lead screw coupled to the second output gear such that a rotational input received by the second output gear causes the second lead screw to rotate and, in turn, causes a second nut threadingly engaged around the second lead screw to translate along the second lead screw.

Description

Cross-references to related applications

[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 565,135, filed March 14, 2024, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure relates to surgical instruments, and more specifically to drive mechanisms for surgical instruments used, for example, in robotic surgical systems. Background Technology

[0003] Robotic surgical systems are increasingly being used in a wide variety of surgical procedures. Some robotic surgical systems include a control console that supports a robotic arm. One or more different surgical instruments can be configured for use with the robotic surgical system and can be selectively mounted onto the robotic arm. The robotic arm provides one or more inputs to the mounted surgical instruments to enable the operation of the mounted surgical instruments.

[0004] The quantity, type, and configuration of inputs provided by the robotic arm of a robotic surgical system are constraints on the design of surgical instruments configured for use with the robotic surgical system. In other words, when designing surgical instruments compatible with and used with the robotic arm of a robotic surgical system, consideration should be given to determining how to utilize the available inputs provided by the robotic arm to achieve the desired functionality of the surgical instruments. Summary of the Invention

[0005] As used herein, the term "distal" refers to the portion described as being further away from the surgeon, while the term "proximal" refers to the portion described as being closer to the surgeon. As used herein, the terms "about," "substantially," etc., are intended to account for manufacturing, material, environmental, usage, and / or measurement tolerances and variations. Furthermore, to the extent consistent, any aspect described herein may be used in conjunction with any or all other aspects described herein.

[0006] According to various aspects of this disclosure, a gearbox assembly for surgical instruments is provided. The gearbox assembly includes a drive gear, a first output gear, a second output gear, a first lead screw, a second lead screw, a first nut, and a second nut. The drive gear is configured to receive a rotational input, the first output gear is configured to receive a rotational input from the drive gear, and the second output gear is configured to receive a rotational input from the first output gear. The first lead screw is coupled to the first output gear such that a rotational input to the first output gear rotates the first lead screw. The first nut is threaded around the first lead screw such that rotation of the first lead screw causes the first nut to translate along the first lead screw. The second lead screw is coupled to the second output gear such that a rotational input to the second output gear rotates the second lead screw. The second nut is threaded around the second lead screw such that rotation of the second lead screw causes the second nut to translate along the second lead screw.

[0007] In one aspect of this disclosure, the drive gear is configured to mesh with the first output gear to provide rotational input to the first output gear.

[0008] In another aspect of this disclosure, the first output gear is configured to mesh with the second output gear to provide a rotary input to the second output gear.

[0009] In another aspect of this disclosure, an energy source is provided, and an input shaft is operatively coupled between the energy source and a drive gear, such that the energy source rotatably drives the input shaft to provide a rotary input to the drive gear. In these aspects, an external input terminal may be provided, and the external input terminal may be operatively coupled between the energy source and the input shaft, such that a rotary drive of the external input terminal provides a rotary input to the input shaft. In these aspects, the input shaft may include a proximal end and a distal end, and the drive gear may be located at the distal end of the input shaft.

[0010] In another aspect of this disclosure, the first lead screw is fixedly engaged with the first output gear, and the second lead screw is fixedly engaged with the second output gear.

[0011] In another aspect of this disclosure, a first nut is connected to a first cable, and a second nut is connected to a second cable. In these aspects, the first and second cables can be configured to cause movement of the surgical instrument when the first and second nuts translate along the first and second guide screws, respectively.

[0012] According to various aspects of this disclosure, a surgical instrument is also provided, comprising a housing, a shaft extending distally from the housing, an end effector assembly extending distally axially, and a gearbox assembly disposed within the housing. The gearbox assembly may be configured similarly to any aspect detailed above or otherwise described herein, such that translation of a first nut along a first lead screw and translation of a second nut along a second lead screw cause movement of the end effector assembly. In these aspects, a first cable and a second cable may be connected to the end effector assembly. Further, in these aspects, the first cable may be connected to a first gripper member of the end effector assembly, and the second cable may be connected to a second gripper member of the end effector assembly. Attached Figure Description

[0013] The following description of various aspects and features of this disclosure is made with reference to the accompanying drawings, wherein the same reference numerals denote the same or corresponding elements in each of the views.

[0014] Figure 1 This is a perspective view of surgical instruments configured to be mounted on a robotic arm of a robotic surgical system, provided in accordance with this disclosure. Figure 2A yes Figure 1 A frontal stereoscopic view of the proximal portion of the surgical instrument, with the outer shell removed; Figure 2B yes Figure 1 Rear stereoscopic view of the proximal portion of the surgical instrument, with the outer shell removed; Figure 3 yes Figure 1 A frontal stereoscopic view of the proximal portion of a surgical instrument, with the outer shell and additional internal components removed; Figure 4 It is configured for releasable acceptance. Figure 1 A schematic illustration of an exemplary robotic surgical system with surgical instruments; Figure 5 yes Figure 1 A front-view stereoscopic view of the gripper drive subassembly of a surgical instrument; Figure 6 yes Figure 1 Rear-view stereoscopic view of the gripper drive sub-assembly of the surgical instrument; Figure 7 yes Figure 1 An exploded perspective view of the gripper drive sub-assembly of a surgical instrument; Figure 8 yes Figure 7 A magnified front-view stereoscopic view of the detailed area "8" in the image; Figure 9 yes Figure 7 A magnified rear-view stereoscopic view of the detailed area "8" in the image; Figure 10 yes Figure 1 An exploded perspective view of the drive rod and locking plate of the gripper drive subassembly of a surgical instrument. Figure 11 yes Figure 7 A magnified 3D view of the detailed area "11" in the image; Figure 12 It is along Figure 1 The longitudinal section view taken by the section line "12-12"; Figure 13 It is along Figure 1 The longitudinal section view taken by section line "13-13"; Figure 14 It is along Figure 3 The transverse cross-sectional view taken by the section line "14-14"; Figure 15 It is along Figure 3 The transverse cross-sectional view taken by the section line "15-15"; Figure 16 It is along Figure 12 A transverse cross-sectional view taken by the section line "16-16"; Figure 17 It is along Figure 12 A transverse cross-sectional view taken by the section line "17-17"; Figure 18 It is along Figure 12 A transverse cross-sectional view taken by the section line "18-18"; Figure 19 It is along Figure 12 A transverse cross-sectional view taken by the section line "19-19"; Figure 20 yes Figure 1 A three-dimensional view of the distal portion of a surgical instrument, wherein the end effector assembly is set in the open position; Figure 21 yes Figure 1 A longitudinal cross-sectional view of another proximal portion of the surgical instrument shows the gripper drive subassembly changing the end effector assembly from an open position to a closed position; Figure 22 yes Figure 1 A three-dimensional view of the distal portion of a surgical instrument, wherein the end effector assembly is positioned in a closed position; Figure 23 yes Figure 21 A longitudinal cross-sectional view of the proximal portion of the surgical instrument, showing the gripper drive subassembly and the end effector assembly in the closed position; Figure 24A This is a top view of the gearbox configuration; Figure 24B yes Figure 24A A front view diagram of the drive gear and a set of output gears of the gearbox, showing the rotation direction of the drive gear and the set of output gears; Figure 25A yes Figure 24A A top view of an alternative configuration of the gearbox; and Figure 25B yes Figure 25A A front view of the gearbox showing the first drive gear, the first set of output gears, the second drive gear, and the second set of output gears, illustrating the rotational directions of the first drive gear, the first set of output gears, the second drive gear, and the second set of output gears. Detailed Implementation

[0015] refer to Figures 1 to 3 The surgical instrument 10 provided according to this disclosure generally includes a housing 20, a shaft 30 extending distally from the housing 20, an end effector assembly 40 extending distally from the shaft 30, and a gearbox assembly 100 disposed within the housing 20 and operatively associated with the end effector assembly 40. The instrument 10 is detailed herein as being configured to work with a robotic surgical system (e.g., robotic surgical system 1000). Figure 4 Articulated electrosurgical clamps used together. However, the aspects and features of the instrument 10 provided in accordance with this disclosure, as detailed below, are equally applicable to use with other suitable surgical instruments and / or in other suitable surgical systems.

[0016] For details, please refer to the following: Figure 1 The housing 20 of the device 10 includes a first body portion 22a and a second body portion 22b, and a proximal panel 24, which cooperate to enclose the gearbox assembly 100 therein. The proximal panel 24 includes orifices defined therein, through which the input ends 110 to 140 of the gearbox assembly 100 extend. A pair of latching levers 26 extend outwardly from the opposite side of the housing 20. Figure 1 (Only one of them is shown in the image) enables the housing 20 to be integrated with surgical systems, such as robotic surgical system 1000. Figure 4 The robotic arm can be releasably engaged. An aperture 28 defined through housing 20 allows thumb wheel 440 to extend through it so that thumb wheel 440 can be manually operated from outside housing 20, thereby allowing manual opening and closing of end effector assembly 40 as detailed below.

[0017] The shaft 30 of the device 10 accordingly includes a distal section 32, a proximal section 34, and an articulated section 36 disposed between the distal section 32 and the proximal section 34. The articulated section 36 includes one or more articulated components 37, such as links, joints, etc. Multiple articulated motion cables 38 (e.g., four (4) articulated motion cables) or other suitable actuators extend through the articulated section 36. More specifically, the articulated motion cable 38 is operatively coupled at its distal end to the distal segment 32 of the shaft 30 and extends proximally from the distal segment 32 of the shaft 30, through the articulated section 36 and the proximal segment 34 of the shaft 30, and into the housing 20. The articulated motion cable 38 is operatively coupled to the articulated motion sub-assembly 200 of the gearbox assembly 100 to enable selective articulation of the distal segment 32 (and therefore the end effector assembly 40) relative to the proximal segment 34 and the housing 20, for example, with respect to at least two axes of articulated motion (e.g., yaw and pitch articulated motions). The articulated motion cable 38 is arranged in a generally rectangular configuration, but other suitable configurations are also contemplated.

[0018] Regarding the articulated movement of the end effector assembly 40 relative to the proximal segment 34 of the shaft 30, the actuation of the articulated motion cables 38 is achieved in pairs. More specifically, to pitch the end effector assembly 40, the upper cable pair 38 is actuated in a similar manner, while the lower cable pair 38 is actuated in a manner similar to each other but opposite to that of the upper cable pair 38. Regarding the yaw articulated movement, the right cable pair 38 is actuated in a similar manner, while the left cable pair 38 is actuated in a manner similar to each other but opposite to that of the right cable pair 38.

[0019] Continue to refer to Figure 1 The end effector assembly 40 accordingly includes a first gripper member 42 and a second gripper member 44. Each gripper member 42, 44 accordingly includes a proximal flange portion 43a, 45a and a distal body portion 43b, 45b. The distal body portions 43b, 45b accordingly define opposing tissue contact surfaces 46, 48. The proximal flange portions 43a, 45a are pivotally connected to each other about a pivot 50 and operably connected to each other via a cam slot assembly 52 (which includes a cam pin slidably received within a cam slot defined in a respective proximal flange portion 43a, 45a of at least one gripper member 42, 44) to allow the gripper member 42 to pivot relative to the gripper member 44 and the distal segment 32 of the shaft 30 between a spaced-apart position (e.g., an open position of the end effector assembly 40) and a proximal position (e.g., a closed position of the end effector assembly 40) to grasp tissue “T” between tissue contact surfaces 46, 48. Figure 20 and Figure 22As an alternative to this single-sided configuration, a double-sided configuration can be provided, in which the two gripper members 42, 44 can pivot relative to each other and relative to the distal segment 32 of the axis 30.

[0020] In embodiments, longitudinally extending tool channels 49 (only the tool channels 49 of gripper member 44 are shown; the tool channels of gripper member 42 are configured in a similar manner) are defined through tissue contact surfaces 46 and 48 of gripper members 42 and 44, respectively. In these embodiments, a tool assembly is provided comprising a tool tube 62 extending from housing 20 through shaft 30 to end effector assembly 40. Figures 12 to 15 ) and a blade (not shown) disposed within the end effector assembly 40 between the gripper members 42, 44, so as to be able to cut the tissue "T" (tissue) gripped between the tissue contact surfaces 46, 48 of the gripper members 42, 44, respectively. Figure 20 and Figure 22 Tool tube 62 ( Figures 12 to 15 The proximal end of the tool drive subassembly 300 is operably coupled to the gearbox assembly 100. Figures 2A to 2B This allows the cutter tube to be selectively actuated, causing the blade (not shown) to reciprocate between the gripper members 42 and 44, thereby cutting the tissue "T" gripped between the tissue contact surfaces 46 and 48. Figure 20 and Figure 22 ).

[0021] Still referencing Figure 1 A drive rod 484 is operatively coupled to a cam slot assembly 52 of the end effector assembly 40, for example, engaging with its cam pin, such that longitudinal actuation of the drive rod 484 causes the gripper member 42 to pivot relative to the gripper member 44 between a spaced-out position and a proximal position. More specifically, pushing the drive rod 484 proximally causes the gripper member 42 to pivot relative to the gripper member 44 toward the proximal position, while pushing the drive rod 484 distally causes the gripper member 42 to pivot relative to the gripper member 44 toward a spaced-out position. However, other suitable mechanisms and / or configurations for pivoting the gripper member 42 relative to the gripper member 44 between a spaced-out position and a proximal position in response to selective actuation of the drive rod 484 are also conceivable. The drive rod 484 extends proximally from the end effector assembly 40 through the shaft 30 and into the housing 20, wherein the drive rod 484 is connected to the gearbox assembly 100 ( Figures 2A to 2B The gripper drive subassembly 400 is operably coupled to enable the end effector assembly 40 to be selectively actuated to grasp tissue “T” therebetween. Figure 20 and Figure 22 And apply a closing force within the appropriate clamping force range, as detailed below.

[0022] The tissue contact surfaces 46 and 48 of the gripper members 42 and 44 are respectively at least partially formed of conductive material and can be excited to different potentials so that electrical energy can be conducted through the tissue "T" grasped therebetween. Figure 20 and Figure 22 However, tissue contact surfaces 46 and 48 can alternatively be configured to supply any suitable energy, such as heat, microwaves, light, ultrasound, or ultrasonic waves, through the tissue "T" held therein. Figure 20 and Figure 22 The instrument 10 defines a conduction path (not shown) through the housing 20 and shaft 30 to an end effector assembly 40, which may include wires, contacts, and / or conductive components such that the tissue contact surfaces 46, 48 of the gripper members 42, 44 can be electrically connected to an energy source (not shown), such as an electrosurgical generator, to supply energy to the tissue contact surfaces 46, 48 to process (e.g., seal) the tissue “T” gripped between the tissue contact surfaces 46, 48. Figure 20 and Figure 22 ).

[0023] For further reference Figure 2A , Figure 2B and Figure 3 As described above, the gearbox assembly 100 is disposed within the housing 20 and includes an articulated motion subassembly 200, a tool drive subassembly 300, and a gripper drive subassembly 400. The articulated motion subassembly 200 is correspondingly operably connected to the first input terminal 110 and the second input terminal 120 of the gearbox assembly 100 and the articulated motion cable 38. Figure 1 Between, such that after receiving appropriate input in the first input terminal 110 and / or the second input terminal 120, the hinged motion subassembly 200 manipulates the cable 38 ( Figure 1 This allows the end effector assembly 40 to be hinged in a desired direction, for example, to pitch and / or yaw the end effector assembly 40.

[0024] The tool drive sub-assembly 300 is operatively connected to the third input terminal 130 of the gearbox assembly 100 and the tool tube 62. Figures 12 to 15 Between, such that after receiving appropriate input at the third input terminal 130, the tool drive subassembly 300 manipulates the tool tube 62 ( Figures 12 to 15 This causes the blade (not shown) to reciprocate between the gripper members 42 and 44, thereby cutting the tissue "T" gripped between the tissue contact surfaces 46 and 48. Figure 20 and Figure 22 ).

[0025] The gripper drive subassembly 400 (described in detail below) is operatively coupled between the fourth input end 140 of the gearbox assembly 100 and the drive rod 484, such that upon receiving appropriate input in the fourth input end 140, the gripper drive subassembly 400 pivots the gripper members 42, 44 between a spaced-apart position and a proximal position to grasp tissue “T” therebetween. Figure 20 and Figure 22 And apply a closing force within the appropriate closing force range.

[0026] Gearbox assembly 100 is configured to operate when instrument 10 is mounted on robotic surgical system 1000. Figure 4 ) and robotic surgical system 1000 ( Figure 4 The gearbox assembly 100 is operably docked to enable robotic operation of the gearbox assembly 100 to provide the functions detailed above. That is, the robotic surgical system 1000 ( Figure 4 Selectively providing input, such as rotational input, to the input terminals 110 to 140 of the gearbox assembly 100 to cause the end effector assembly 40 to articulate, thereby organizing the "T" ( Figure 20 and Figure 22 ) clamping between gripper members 42, 44 and / or cutting the tissue "T" clamped between gripper members 42, 44 Figure 20 and Figure 22 However, it is also conceivable that the gearbox assembly 100 is configured to interface with any other suitable surgical system (e.g., a manual surgical handpiece, a motorized surgical handpiece, etc.). For the purposes of this document, the robotic surgical system 1000 is generally described. Figure 4 ).

[0027] Turning Figure 4 The robotic surgical system 1000 is configured for use in accordance with this disclosure. Aspects and features of the robotic surgical system 1000 that are not closely related to understanding this disclosure have been omitted to avoid obscuring aspects and features of this disclosure with unnecessary detail.

[0028] The robotic surgical system 1000 generally includes: multiple robotic arms 1002, 1003; a control unit 1004; and an operation console 1005 connected to the control unit 1004. The operation console 1005 may include: a display device 1006, which can be configured to specifically display three-dimensional images; and manual input devices 1007, 1008, through which a person, such as a surgeon, can remotely operate the robotic arms 1002, 1003 in a first operating mode. The robotic surgical system 1000 can be configured for a patient 1013 lying on a patient table 1012 to be treated minimally invasively. The robotic surgical system 1000 may further include a database 1014, particularly connected to the control unit 1004, in which preoperative data and / or anatomical atlases from the patient 1013 are stored.

[0029] Each of the robotic arms 1002 and 1003 may include multiple components connected by a joint, and a mounted device that may be, for example, a surgical instrument "ST". One or more of the surgical instruments "ST" may be instrument 10 ( Figure 1 Thus, such functionality is provided on the robotic surgical system 1000.

[0030] Robotic arms 1002 and 1003 can be driven by an electric drive device (e.g., a motor) connected to a control device 1004. The control device 1004 (e.g., a computer) can be configured to specifically activate the motors by means of a computer program, such that the robotic arms 1002 and 1003, and therefore the surgical instruments "ST" mounted thereon, perform desired movements and / or functions based on corresponding inputs from manual input devices 1007 and 1008, respectively. The control device 1004 can also be configured to regulate the movement of the robotic arms 1002 and 1003 and / or the motors.

[0031] refer to Figures 5 to 7 and Figures 12 to 19 The gripper drive sub-assembly 400 of the gearbox assembly 100 is generally shown as including an input shaft 410, an input gear 420, a drive gear 430, a thumb wheel 440, a spring force assembly 450, and a drive lever assembly 480.

[0032] The input shaft 410 includes a proximal portion 412 operably coupled to the fourth input terminal 140 and a distal portion 414 on which an input gear 420 is engaged, such that a rotary input provided to the fourth input terminal 140 drives rotation of the input shaft 410, thereby driving rotation of the input gear 420. The input gear 420 is configured to mesh with a modified circular gear 432 of the drive gear 430, such that rotation of the input gear 420, for example in response to a rotary input provided at the fourth input terminal 140, causes the drive gear 430 to rotate in the opposite direction (see [link]). Figure 16 The thumbwheel 440 is also configured to mesh with the modified circular gear 432 of the drive gear 430, such that rotation of the thumbwheel 440 causes the drive gear 430 to rotate in the opposite direction, thereby enabling manual operation of the drive gear 430 via the thumbwheel 440 (see [link]). Figure 16 ).

[0033] Also refer to Figure 11 As described above, the drive gear 430 includes a trimmed circular gear 432. The drive gear 430 further includes a lead screw 434 that is fixedly engaged (e.g., integrally formed) with the trimmed circular gear 432, such that rotation of the trimmed circular gear 432 causes a similar rotation of the lead screw 434.

[0034] For further reference Figure 8 and Figure 9 The spring force assembly 450 includes a proximal hub 452, a distal hub 454, a compression spring 456, and a spring washer 458. The spring force assembly 450 further includes a pair of guide rods 470.

[0035] The proximal hub 452 and distal hub 454 of the spring force assembly 450 can be identical components, oriented, positioned, and / or coupled to other components in different ways to provide different functions while reducing the number of different components that need to be manufactured. The features of the proximal hub 452 and distal hub 454 are described in detail below to the extent necessary to understand this disclosure, and therefore, while some features may be described in detail with respect to only one of the proximal hub 452 or distal hub 454 and its associated function, similar features may be provided on the other of the proximal hub 452 or distal hub 454 that does not have an associated function. Alternatively, the proximal hub 452 and distal hub 454 can be manufactured as separate components.

[0036] The proximal hub 452 and distal hub 454 of the spring force assembly 450 each include a body 461 defining a cavity 462 and a retainer guide 463 extending radially outward from the opposite side of the body 461. Each retainer guide 463 defines a groove 464 and includes a shoulder 465 extending into the corresponding groove 464. The proximal hub 452 and distal hub 454 are oriented relative to each other such that the open ends of the cavity 462 face each other and the shoulders 465 of each pair of retainer guides 463 of the proximal hub 452 and distal hub 454 face away from each other.

[0037] The proximal hub 452 further includes a lateral slot 466 defined therethrough, which is configured to receive a locking plate 482 of the drive rod assembly 480, as detailed below, to secure the locking plate 482 and thus secure the proximal portion of the drive rod 484 relative to the proximal hub 452 (see [link to details]). Figure 18 and Figure 19 Once engaged in this manner, the drive rod 484 is locked in a position coaxially arranged through the near hub 452, the far hub 454, the compression spring 456, and the drive gear 430.

[0038] The distal hub 454 defines a threaded center bore 468 through its body 461. The threaded center bore 468 receives the lead screw 434 of the drive gear 430 through it in a threaded engagement manner, such that rotation of the lead screw 434 will drive the distal hub 454 to translate longitudinally along the lead screw 434.

[0039] A compression spring 456 is disposed between a proximal hub 452 and a distal hub 454, with a proximal portion disposed within a cavity 461 of the proximal hub 452 and a distal portion disposed within a cavity 461 of the distal hub 454. At least a portion of the compression spring 456 is disposed around and / or configured to receive a portion passing through a lead screw 434 of the drive gear 430. A spring washer 458 is positioned within the cavity 461 of the proximal hub 452, between the proximal hub 452 and the compression spring 456, but other configurations are also contemplated.

[0040] Each guide bar 470 is slidably received within a groove 464 of a corresponding pair of retainer guides 463 of the proximal hub 452 and the distal hub 454. Each guide bar 470 includes a pair of spaced-apart rims 472, 474 engaged thereon, these rims being configured to abut against a shoulder 465 of the corresponding retainer guide 463, thereby defining a maximum distance between the proximal hub 452 and the distal hub 454. However, the proximal hub 452 and / or the distal hub 454 are permitted to slide along the guide bar 470 toward each other, as detailed below.

[0041] refer to Figure 10 and Figure 19 , combined Figures 5 to 7 The drive lever assembly 480 includes a locking plate 482 and a drive lever 484. The locking plate 482 defines a central keyhole 485 and a pair of slots 486 (e.g., arcuate slots) defined on the distal sides of the locking plate 482 on either side of the central keyhole 485. The locking plate 482 is configured to insert through a lateral slot 466 of the proximal hub 452, and once installed therein, a portion of a spring washer 458 is configured to be received within the slot 486 to securely engage the locking plate 482 within the proximal hub 452. The spring washer 458 is held in place within the slot 486 by a compression spring 456, which is pre-compressed at the maximum distance between the proximal hub 452 and the distal hub 454 (defined by the rims 472, 474 of the guide rod 470 and the shoulder 465 of the retainer guide 463).

[0042] As described above, the drive lever 484 includes components operably coupled to the end effector assembly 40. Figure 1 The distal portion of the cam slot assembly 52. ​​The drive rod 484 extends proximally through the shaft 30, housing 20, and gearbox assembly 100 (see...). Figures 1 to 3 Furthermore, the proximal portion of the drive rod 484 engages within the locking plate 482. More specifically, the drive rod 484 defines a waist 488 toward its proximal end, which is configured, for example, to longitudinally translate into the central keyhole 485 via the drive rod 484 until the waist 488 aligns with the central keyhole 485 of the locking plate 482, after which the drive rod 484 moves laterally relative to the locking plate 482 and lockably engages within the central keyhole 485, thereby securing the proximal portion of the drive rod 484 relative to the locking plate 482 and thus securing it relative to the proximal hub 452 due to the locking plate 482 engaging within the proximal hub 452.

[0043] Turning Figure 3 , Figures 12 to 15 and Figure 17 The tool drive subassembly 300 includes an input shaft 310, an input gear 320, a center gear 330 defining external and internal threads, and a lead screw 340. The input shaft 310 extends parallel and offset relative to the input shaft 410 and includes a third input end 130 operably coupled to the gearbox assembly 100. Figure 2A and Figure 2B The input shaft 310 is driven by a rotary input provided to the third input terminal 130, which in turn drives the rotation of the input gear 320 via a proximal portion 312 and a distal portion 314 on which the input gear 320 is engaged. The input gear 320 is configured to mesh with the external thread of the center gear 330. The center gear 330 is coaxial with the drive gear 430 and is positioned distal to the drive gear.

[0044] The lead screw 340 extends through and threadedly engages with the central gear 330, such that rotation of the central gear 330, for example, in response to a rotational input provided to the third input terminal 130, causes the lead screw 340 to translate. The lead screw 340 is fixedly engaged around the proximal portion of the tool tube 62, such that translation of the lead screw 340 causes translation of the tool tube 62, for example, thereby causing the cutting tool (not shown) to be positioned within the gripper members 42, 44. Figure 1 The lead screw 340 and the tool tube 62 are arranged coaxially around the drive rod 484.

[0045] refer to Figures 5 to 7 and Figures 20 to 23 In use, the gripper components 42 and 44 are initially positioned at a distance from each other. Figure 20 And correspondingly, the near hub 452 and the far hub 454 are positioned at the farthest point, so that the drive rod 484 is positioned at the farthest point (see...). Figures 12 to 15 Furthermore, in this position, the compression spring 456 is set to be in a minimum compression state; however, as described above, even in the minimum compression state, the compression spring 456 is also partially compressed because it remains in a pre-compression configuration between the proximal hub 452 and the distal hub 454.

[0046] In response to an input that closes the end effector assembly 40, such as a rotary input to the fourth (i.e., gripper) input end 140 or a manual input to the rotating wheel 440, the drive shaft 410 rotates, thereby rotating the input gear 420, which in turn rotates the drive gear 430, causing the distal hub 454 to translate proximally toward the proximal hub 452 (see...). Figure 21 ). refer to Figure 21 The proximal translation of the distal hub 454 pushes it against the compression spring 456. Initially, with the force resisting the approach of the gripper members 42, 44 below a threshold corresponding to the spring value of the compression spring 456, the closing force applied by the gripper members 42, 44 is relatively low, causing the proximal push of the distal hub 454 against the compression spring 456 to push the compression spring 456 proximal, which in turn pushes the locking plate 482 and thus the drive rod 484 proximal, causing the gripper member 42 to pivot relative to the gripper member 44 from a spaced-out position toward an approaching position, thereby gripping tissue "T" therebetween. Figure 20 and Figure 22 ).

[0047] refer to Figures 5 to 7 , Figure 22 and Figure 23As the gripper members 42 and 44 move closer together to grasp the tissue "T", the force resisting the approach of the gripper members 42 and 44 (e.g., the tissue "T" resisting compression) can reach a threshold, and therefore the closing force applied by the gripper members 42 and 44 can reach the corresponding threshold. To maintain the closing force applied by the gripper members 42 and 44 within a closing force range, for example from approximately 3 kg / cm², [further measures are needed]. 2 Approximately 16 kg / cm 2 Beyond this point, even if further rotational input is applied to the fourth input terminal 140, it will still inhibit the gripper members 42 and 44 from applying further closing force. More specifically, and referring to... Figure 23 Once the threshold is reached, further rotational input to the fourth input terminal 140 causes the drive shaft 410, input gear 420, and drive gear 430 to rotate, thereby translating the distal hub 454 further proximally into the compression spring 456. However, instead of pushing the proximal hub 452 further proximally to allow the gripper members 42, 44 to continue moving closer and increasing the closing force applied therebetween, the compression spring 456 is compressed, allowing the proximal hub 452 and thus the drive rod 484 to remain in place, thereby suppressing the application of additional closing force between the gripper members 42, 44.

[0048] refer to Figure 22 When tissue "T" is gripped between gripper members 42 and 44 under appropriate closing force, energy can be supplied to gripper members 42 and 44 to process (e.g., seal) tissue "T". Subsequently, a blade (not shown) can be advanced between gripper members 42 and 44 to cut the processed tissue "T". See also... Figure 14 and Figure 17 To advance the blade (not shown), a rotary input is provided to input end 130 to drive the rotation of input shaft 310, input gear 320, and center gear 330, thereby causing lead screw 340 to translate distally, causing cutter tube 62 to also translate distally, so that the blade (not shown) is advanced between gripper members 42, 44 to cut the processed tissue "T". Alternatively, tissue "T" can be cut without first processing tissue "T", and / or tissue "T" can be processed without subsequent cutting.

[0049] Once the tissue “T” has been cut, a reverse rotational input is provided to input 130 to return the blade (not shown) to its initial position, i.e., in the body portions 43b and 45b of the gripper members 42 and 44 (see [link to relevant documentation]). Figure 1 The proximal side of the ) is then provided with the input end 140 (or the rotating wheel 440) to cause the gripper members 42, 44 to return to the spaced-out position to release the sealed and / or cut tissue.

[0050] refer to Figures 24A to 25BAn alternative configuration of gearbox assembly 500, replacing gearbox assembly 100, is shown. The configuration of gearbox assembly 500 allows any one of inputs 110 to 140 to drive two movements. In some applications, the surgical instrument 10 may require additional movements that cannot be achieved by the four inputs, each controlling a single movement. For example, in a suturing operation, the first gripper member 42 of the end effector assembly 40 includes a first needle buckle (not shown), and the second gripper member 44 of the end effector assembly 40 includes a second needle buckle (not shown). Using gearbox assembly 500, the movement of the first and second needle buckles will occur simultaneously and in opposite directions, causing the first needle buckle to extend and the second needle buckle to retract. Furthermore, it may be desirable to combine the two movements into a single input, thereby freeing up the remaining input to perform additional operations.

[0051] refer to Figures 24A to 24B The input shaft 510 includes a proximal portion 512 operably coupled to or coupled to the first motor 502. For example... Figure 24A As shown, the input shaft 510 and the first motor 502 can be connected together via any of the input terminals 110 to 140. The input shaft 510 includes a distal portion 514 on which a drive gear 520 is engaged, such that a rotational input provided by the first motor 502 drives the rotation of the input shaft 510, thereby driving the rotation of the drive gear 520. The drive gear 520 is configured to mesh with a first output gear 530, such that rotation of the drive gear 520, for example, in response to a rotational input provided by the first motor 502, causes the first output gear 530 to rotate in the opposite direction (see [link]). Figure 24B The second output gear 540 is configured to mesh with the first output gear 530, such that rotation of the first output gear 530 causes the second output gear 540 to rotate in the opposite direction to that of the first output gear 530 (see [link]). Figure 24B ).

[0052] The first output gear 530 includes a first lead screw 532 fixedly engaged (e.g., integrally formed) with the first output gear 530, such that rotation of the first output gear 530 causes a similar rotation of the first lead screw 532. The first lead screw 532 is threadedly engaged with a first nut 534, such that rotation of the first lead screw 532 drives the first nut 534 to translate longitudinally along the first lead screw 532.

[0053] Similarly, the second output gear 540 includes a second lead screw 542 fixedly engaged with the second output gear 540, such that rotation of the second output gear 540 causes a similar rotation of the second lead screw 542. The second lead screw 542 is threadedly engaged with a second nut 544, such that rotation of the second lead screw 542 drives the second nut 544 to translate longitudinally along the second lead screw 542.

[0054] The first nut 534 and the second nut 544 are each attached to corresponding cables 550a and 550b to cause movement of the end effector 40 of the surgical instrument 10. For example, when the input shaft 510 rotates, the first nut 534 can be moved away from the first output gear 530, while the second nut 544 can be moved towards the second output gear 540. Figure 24A As indicated by the arrows in the diagram. Cable 550a can be connected to both the first nut 534 and a first instrument or component (not shown) disposed within the first gripper member 42 of the end effector 40, while cable 550b can be connected to both the second nut 544 and a second instrument or component (not shown) disposed within the second gripper member 44 of the end effector 40. The first and second instruments can be any of the following: a suture needle loop, a monopole hook, a scalpel blade, etc. Rotation of the first output gear 530 and the resulting translation of the first nut 534 can cause cable 550a to extend or extend the first instrument. The resulting rotation of the second output gear 540 in the opposite direction to the first output gear 530 and the corresponding translation of the second nut 544 can cause cable 550b to retract the second instrument. Although separate cables 550a and 550b are shown, it is conceivable that a single cable (not shown) could alternatively be connected to both the first nut 534 and the second nut 544 to cause movement of the end effector 40.

[0055] In contrast to the direct meshing of drive gear 520, first output gear 530, and second output gear 540, an auxiliary gear (not shown) may be configured to mesh with any one of drive gear 520, first output gear 530, and second output gear 540, and / or mesh between them. The auxiliary gear may affect the timing, speed, and travel distance of first nut 534 and second nut 544. To further alter the speed and travel distance of first nut 534 and second nut 544, the sizes of first output gear 530 and second output gear 540 may differ from each other, thereby allowing first output gear 530 and second output gear 540 to complete a full rotation at different rates.

[0056] Figures 25A to 25B The configuration of a gearbox assembly 500 is shown, which has multiple input shafts, each driving two motions. Although Figure 25A and Figure 25B Two input axes are shown, but it is conceivable that more than two input axes could be used to drive two motions simultaneously. Figure 25A and Figure 25B The configuration of the gearbox assembly 500 is modified by including a second motor 602. Figures 24A to 24B The configuration of the gearbox assembly 500 is such that the second motor drives the input shaft 610 in a manner similar to that of the first motor 502 driving the input shaft 510.

[0057] The input shaft 610 includes a proximal portion 612 operably coupled to or coupled to a second motor 602, such that a rotary input provided by the second motor 602 drives rotation of the input shaft 610. Figure 25A As shown, the input shaft 610 and the second motor 602 can be connected together via any of the input terminals 110 to 140. The input shaft 610 further includes a distal portion 614 on which a drive gear 620 is engaged. The drive gear 620 meshes with a first output gear 630, and the first output gear 630 meshes with a second output gear 640. Rotation of the drive gear 620, for example, in response to a rotational input provided by the second motor 602, causes the first output gear 630 to rotate in the opposite direction to the drive gear 620 (see [link to diagram]). Figure 25B Furthermore, the rotation of the first output gear 630 causes the second output gear 640 to rotate in the opposite direction to that of the first output gear 630 (see...). Figure 25B ).

[0058] The first output gear 630 includes a first lead screw 632 fixedly engaged (e.g., integrally formed) with the first output gear 630, such that rotation of the first output gear 630 causes a similar rotation of the first lead screw 632. The first lead screw 632 is threadedly engaged with a first nut 634, such that rotation of the first lead screw 632 drives the first nut 634 to translate longitudinally along the first lead screw 632. Similarly, the second output gear 640 includes a second lead screw 642 fixedly engaged (e.g., integrally formed) with the second output gear 640, such that rotation of the second output gear 640 causes a similar rotation of the second lead screw 642. The second lead screw 642 is threadedly engaged with a second nut 644, such that rotation of the second lead screw 642 drives the second nut 644 to translate longitudinally along the second lead screw 642.

[0059] First nut 534, second nut 544, first nut 634, and second nut 644 can each be attached to a cable to cause movement of the end effector 40 of the surgical instrument 10. Although cables 550a and 550b are shown connected to the first nut 534 and second nut 544 respectively, it is conceivable that the first nut 634 and second nut 644 can also be connected to a corresponding cable (not shown). In several respects, the cable can function in a manner similar to the articulated motion cable 38, and can enable selective articulated movement of the distal segment 32 of the end effector 40 relative to the proximal segment 34 and the housing 20 on at least two axes. For example, rotation of the first input shaft 510 and the second input shaft 610 can control the pitch and yaw articulated movements of the distal segment 32.

[0060] In other respects, the cables enable rotation of the first input shaft 510 and the second input shaft 610 to control the articulated movement of a controllable tube (not shown) located at the end effector 40. A first nut 534 can be connected to cable 550a, and a second nut 544 can be connected to cable 550b. When the input shaft 510 rotates, the first nut 534 can be moved away from the first output gear 530, while the second nut 544 can be moved towards the second output gear 540, such as... Figure 25A As indicated by the arrows. Each of cables 550a and 550b can be connected to a controllable tube to control its vertical movement. A first nut 634 can be connected to a third cable, and a second nut 644 can be connected to a fourth cable. When the input shaft 610 rotates, the first nut 634 can be moved away from the first output gear 630, while the second nut 644 can be moved towards the second output gear 640, as shown by the arrows. Figure 25A As shown by the arrows in the diagram. Each of the third and fourth cables can be connected to the operable tube to control its horizontal movement.

[0061] Similar to drive gear 620, first output gear 630, and second output gear 640, an additional gear (not shown) can be configured to mesh with any one of drive gear 620, first output gear 630, and second output gear 640, and / or between them, to change the timing, speed, and travel distance of first nut 634 and second nut 644. In addition to or instead of the additional gear, the speed and travel distance of first nut 634 and second nut 644 can be changed by having different sizes for first output gear 630 and second output gear 640.

[0062] It should be understood that various modifications can be made to the embodiments disclosed herein. Therefore, the above description should not be construed as limiting, but rather as illustrative of the various embodiments only. Other modifications will be contemplated by those skilled in the art within the scope and spirit of the appended claims.

Claims

1. A gearbox assembly for surgical instruments, the gearbox assembly comprising: A drive gear, which is used to receive rotary input; A first output gear is used to receive rotary input from the drive gear; A first lead screw is connected to the first output gear, such that the rotational input received by the first output gear causes the first lead screw to rotate; A first nut is threaded around the first lead screw, such that rotation of the first lead screw causes the first nut to translate along the first lead screw. A second output gear is used to receive rotary input from the first output gear; A second lead screw, connected to the second output gear, such that the rotational input received by the second output gear causes the second lead screw to rotate; and A second nut is threaded around the second lead screw, such that rotation of the second lead screw causes the second nut to translate along the second lead screw.

2. The gearbox assembly according to claim 1, wherein, The drive gear is configured to mesh with the first output gear to provide the rotational input to the first output gear.

3. The gearbox assembly according to claim 1, wherein, The first output gear is configured to mesh with the second output gear to provide the rotational input to the second output gear.

4. The gearbox assembly of claim 1, further comprising an energy source and an input shaft operably connected between the energy source and the drive gear, such that the energy source rotatably drives the input shaft to provide the rotational input to the drive gear.

5. The gearbox assembly of claim 4, further comprising an external input terminal operably connected between the energy source and the input shaft, such that a rotational drive of the external input terminal provides the rotational input to the input shaft.

6. The gearbox assembly according to claim 4, wherein, The input shaft includes a proximal end and a distal end, wherein the drive gear is disposed at the distal end of the input shaft.

7. The gearbox assembly according to claim 1, wherein, The first lead screw is fixedly engaged with the first output gear, and the second lead screw is fixedly engaged with the second output gear.

8. The gearbox assembly according to claim 1, wherein, The first nut is connected to the first cable, and the second nut is connected to the second cable.

9. The gearbox assembly according to claim 8, wherein, When the first nut and the second nut translate along the first guide screw and the second guide screw respectively, the first cable and the second cable cause the surgical instrument to move.

10. A surgical instrument, comprising: case; A shaft that extends distally from the housing; An end effector assembly extending distally from the axial direction; as well as Gearbox assembly, disposed within the housing, the gearbox assembly comprising: A drive gear, which is used to receive rotary input; A first output gear is used to receive rotary input from the drive gear; A first lead screw is connected to the first output gear, such that the rotational input received by the first output gear causes the first lead screw to rotate; A first nut is threaded around the first lead screw, such that rotation of the first lead screw causes the first nut to translate along the first lead screw. A second output gear is used to receive rotary input from the first output gear; A second lead screw, connected to the second output gear, such that the rotational input received by the second output gear causes the first lead screw to rotate; and A second nut, threaded around the second lead screw, causes rotation of the second lead screw to translate the second nut along the lead screw. The translation of the first nut along the first lead screw and the translation of the second nut along the second lead screw cause the movement of the end effector assembly.

11. The surgical instrument according to claim 10, wherein, The drive gear is configured to mesh with the first output gear to provide the rotational input to the first output gear.

12. The surgical instrument according to claim 10, wherein, The first output gear is configured to mesh with the second output gear to provide the rotational input to the second output gear.

13. The surgical instrument according to claim 10, wherein, The gearbox assembly further includes an energy source and an input shaft operatively connected between the energy source and the drive gear, such that the energy source rotatably drives the input shaft to provide the rotary input to the drive gear.

14. The surgical instrument according to claim 13, wherein, The gearbox assembly further includes an external input terminal operatively coupled between the energy source and the input shaft, such that a rotational drive of the external input terminal provides the rotational input to the input shaft.

15. The surgical instrument according to claim 13, wherein, The input shaft of the gearbox assembly includes a proximal end and a distal end, wherein the drive gear is disposed at the distal end of the input shaft.

16. The surgical instrument according to claim 10, wherein, The first lead screw is fixedly engaged with the first output gear, and the second lead screw is fixedly engaged with the second output gear.

17. The surgical instrument according to claim 10, wherein, The first nut is connected to the first cable, and the second nut is connected to the second cable.

18. The surgical instrument according to claim 17, wherein, The first cable and the second cable are connected to the end effector assembly.

19. A surgical instrument, comprising: case; A shaft that extends distally from the housing; An end effector assembly extending distally from the axial direction; as well as Gearbox assembly, disposed within the housing, the gearbox assembly comprising: An input shaft having a proximal end and a distal end; A drive gear is disposed at the distal end of the input shaft and configured to receive rotary input from the input shaft; A first output gear, the first output gear being configured to receive a rotary input from the drive gear; A first lead screw is connected to the first output gear, such that the rotational input received by the first output gear causes the first lead screw to rotate; A first nut is threaded around the first lead screw, such that rotation of the first lead screw causes the first nut to translate along the first lead screw. A second output gear is configured to receive a rotational input from the first output gear; The second lead screw is connected to the second output gear, such that the rotational input received by the second output gear causes the first lead screw to rotate; A second nut is threaded around the second lead screw, such that rotation of the second lead screw causes the second nut to translate along the second lead screw. A first cable, the first cable being connected to the first nut, the first cable being operably connected to the end effector assembly; and A second cable, which is connected to the second nut, is operatively connected to the end effector assembly. The translation of the first nut along the first lead screw and the translation of the second nut along the second lead screw respectively cause the movement of the end effector assembly via the first cable and the second cable.

20. The surgical instrument of claim 19, wherein, The first cable is connected to the first gripper member of the end effector assembly, and the second cable is connected to the second gripper member of the end effector assembly.

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