Manual end effector activation for robotic surgical systems

Abstract

To provide manual end effector activation for robotic surgical systems.SOLUTION: A robotic surgical instrument includes a housing having a shaft extending therefrom. A spring compression assembly is supported within the housing and includes: a proximal hub configured to secure a drive rod disposed therethrough, the proximal hub including teeth; a distal hub spaced from the proximal hub and including teeth; and a compression spring mounted between the proximal and distal hubs. A drive gear includes a proximal portion extending therefrom having threads disposed thereabout configured to engage the teeth of the proximal and distal hubs such that rotation thereof translates the hubs relative to one another and actuates the end effector assembly. A thumb wheel is included that has a portion exposed outside the housing for external manipulation thereof. The thumb wheel is selectively positionable between a disengaged position spaced relative to the drive gear and an engaged position to matingly engage the drive gear.SELECTED DRAWING: None

Description

Technical Field

[0001] The present disclosure relates to surgical instruments, and more particularly to a sealing configuration for surgical instruments, such as for use in a robotic surgical system.

Background Art

[0002] Robotic surgical systems are being increasingly utilized in a variety of different surgical procedures. Some robotic surgical systems include a console that supports robotic arms. One or more different surgical instruments are configured for use with the robotic surgical system and may be selectively attachable to the robotic arm. The robotic arm provides one or more inputs to the attached surgical instrument to enable operation of the attached surgical instrument.

[0003] A surgical instrument or a portion thereof may be configured as a disposable instrument or a portion that is discarded after use, or may be configured as a reusable instrument or a portion that is cleaned and sterilized during use. Regardless of the configuration of the surgical instrument, the console and robotic arm are capital equipment configured for long-term repeated use. The console and robotic arm are protected by a sterilization barrier during use and / or can be wiped clean after use to ensure cleanliness for subsequent use.

[0004] End effector assemblies used in various surgical procedures often need to be manually operable by operating staff for cleaning and sterilization and / or to operably engage various hardware to robotic equipment. As a result, robotic surgical instruments need to be designed and manufactured with this in mind.

Summary of the Invention

Means for Solving the Problems

[0005] As used herein, the term "distal" refers to the portion of the object being described that is farthest from the operator (whether a human surgeon or a surgical robot), and the term "proximal" refers to the portion of the object being described that is closest to the operator. As used herein, terms such as "about," "substantially," etc. are meant to account for manufacturing, material, environmental, use, and / or measurement tolerances and deviations, and may include differences of up to 10% in any case.

[0006] According to an aspect of the present disclosure, provided is a robotic surgical instrument including a housing having a shaft extending therefrom, the shaft including a drive rod extending therethrough and configured to actuate an end effector assembly upon translation of the drive rod. A spring compression assembly is supported within the housing and includes a proximal hub configured to secure the proximal end of the drive rod disposed therethrough, the proximal hub including a plurality of teeth disposed along its inner peripheral surface, a distal hub spaced from the proximal hub and including a plurality of teeth disposed along its inner peripheral surface, and a compression spring mounted between the proximal hub and the distal hub. A drive gear is included having a proximal portion extending therearound with a plurality of threads configured to matingly engage corresponding teeth of the proximal and distal hubs, rotation of which translates the proximal and distal hubs relative to each other and actuates the end effector assembly. A thumb wheel is included having a portion exposed outside the housing for external operation. The thumb wheel is selectively positionable between a first disengaged position spaced from the drive gear and a second engaged position matingly engaged with the drive gear to enable manual actuation of the end effector assembly.

[0007] In an aspect according to the present disclosure, the drive gear is configured to matingly engage a corresponding gear of an input shaft operably connected to a drive input portion adapted to connect to a robotic surgical system.

[0008] In aspects according to the present disclosure, the thumbwheel is biased to a disengaged position. In other aspects according to the present disclosure, moving the thumbwheel relative to the housing and rotating the thumbwheel causes the drive gear to rotate in response, whereby the proximal hub translates relative to the distal hub to actuate the end effector assembly. In still other aspects according to the present disclosure, the translation of the proximal hub relative to the distal hub moves a drive rod to actuate the end effector assembly.

[0009] In aspects according to the present disclosure, moving the thumbwheel relative to the housing and rotating the thumbwheel causes the drive gear to rotate in response, and then the corresponding gear of an input shaft operably connected to a drive input adapted to connect to a robotic surgical system rotates.

[0010] In aspects according to the present disclosure, the end effector assembly includes a pair of first and second jaw members, and at least one of the jaw members is movable relative to the other of the jaw members.

[0011] Provided in accordance with aspects of the present disclosure is a robotic surgical instrument including a housing having a shaft extending therefrom that includes an end effector assembly at its distal end, the shaft being configured to actuate the end effector assembly during translation and including a drive rod extending therethrough. A spring compression assembly is supported within the housing and includes a proximal hub configured to secure the proximal end of the drive rod disposed therethrough, the proximal hub including a plurality of teeth disposed along its inner circumferential surface, a distal hub spaced from the proximal hub and including a plurality of teeth disposed along its inner circumferential surface, and a compression spring mounted between the proximal hub and the distal hub. A drive gear is included having a proximal portion extending therearound with a plurality of threads configured to matingly engage corresponding teeth of the proximal and distal hubs, rotation of which translates the proximal and distal hubs relative to each other and actuates the end effector assembly. A drive input shaft is included having an input gear configured to matingly engage the drive gear, rotation of the drive input shaft correspondingly rotating the drive gear, the drive input shaft including a drive input portion including a mechanical contact surface disposed therearound. A thumb wheel is included having a portion exposed outside the housing for external operation. The thumb wheel includes a corresponding mechanical contact surface disposed around its inner circumference, the mechanical contact surface of the drive input shaft being configured to matingly engage the corresponding mechanical contact surface of the thumb wheel during selective translation of the thumb wheel. The thumb wheel is selectively translatable between a first disengaged position spaced from the mechanical contact surface disposed on the drive input shaft and a second engaged position matingly engaging the thumb wheel with the drive input shaft to enable manual actuation of the end effector assembly.

[0012] In an aspect according to the present disclosure, the thumbwheel is biased in the disengaged position. In other aspects according to the present disclosure, when the thumbwheel is translated along the drive input shaft and rotated, the drive input shaft and the drive gear are correspondingly rotated, thereby translating the proximal hub relative to the distal hub to operate the end effector assembly. In still other aspects according to the present disclosure, the translation of the proximal hub relative to the distal hub moves the drive rod to operate the end effector assembly.

[0013] In an aspect according to the present disclosure, the end effector assembly includes a pair of first and second jaw members, and at least one of the jaw members is movable relative to the other of the jaw members. In an aspect according to the present disclosure, the drive input shaft is configured to engage and mate with a corresponding plurality of teeth disposed along the inner circumferential surface of the thumbwheel during selective translation of the thumbwheel, and includes a plurality of castellations defined therearound.

[0014] In an aspect according to the present disclosure, the thumbwheel is disposed distally of the spring compression assembly. In other aspects according to the present disclosure, movement of the thumbwheel engages a plurality of teeth with corresponding plurality of castellations defined around the drive input shaft in the distal direction. For example, the present application provides the following items. (Item 1) A robotic surgical instrument, A housing having a shaft extending from the housing, the distal end of the shaft including an end effector assembly, the shaft including a drive rod, the drive rod extending through the shaft and configured to operate the end effector assembly upon translation of the drive rod, the housing; A spring compression assembly supported within the housing, A proximal hub configured to secure the proximal end of the drive rod disposed through the hub and including a plurality of teeth disposed along its inner circumferential surface, the proximal hub; A distal hub spaced from the proximal hub and including a plurality of teeth disposed along its inner circumferential surface, A compression spring mounted between the proximal hub and the distal hub, and a spring compression assembly including the same, A drive gear including a plurality of threads disposed around it, including a proximal portion extending therefrom, and configured to fit and engage with the corresponding plurality of teeth of the proximal and distal hubs, so that its rotation translates the proximal and distal hubs relative to each other and actuates the end effector assembly, a drive gear, A thumbwheel having at least a portion exposed outside the housing for its external operation, and a thumbwheel selectively positionable between a first disengaged position spaced from the drive gear and a second engaged position fitting and engaging with the drive gear to enable manual actuation of the end effector assembly, a robotic surgical instrument comprising the same. (Item 2) The drive gear of the robotic surgical instrument according to the above item, configured to fit and engage with a corresponding gear of an input shaft operably connected to a drive input portion adapted to be connected to a robotic surgical system. (Item 3) The robotic surgical instrument according to any one of the above items, wherein the thumbwheel is biased in the disengaged position. (Item 4) Moving the thumbwheel relative to the housing and correspondingly rotating the thumbwheel rotates the drive gear, thereby translating the proximal hub relative to the distal hub and actuating the end effector assembly, the robotic surgical instrument according to any one of the above items. (Item 5) The robotic surgical instrument according to any one of the above items, wherein the translation of the proximal hub relative to the distal hub moves the drive rod and actuates the end effector assembly. (Item 6) Moving the thumbwheel relative to the housing and correspondingly rotating the thumbwheel rotates the drive gear, thereby operably connecting to a drive input portion adapted to be connected to a robotic surgical system and rotating a corresponding gear of an input shaft. The robotic surgical instrument according to any one of the above items. (Item 7) The robotic surgical instrument according to any one of the above items, wherein the end effector assembly includes a pair of first and second jaw members, and at least one of the jaw members is movable relative to the other of the jaw members. (Item 8) A robotic surgical instrument, A housing having a shaft extending from the housing, including an end effector assembly at a distal end of the shaft, the shaft including a drive rod, the drive rod extending through the shaft, and configured to operate the end effector assembly upon translation of the drive rod. A housing, A spring compression assembly supported within the housing, A proximal hub configured to fix a proximal end of the drive rod disposed therethrough, and including a plurality of teeth disposed along an inner circumferential surface thereof. A proximal hub, A distal hub spaced from the proximal hub and including a plurality of teeth disposed along an inner circumferential surface thereof. A spring compression assembly including a compression spring mounted between the proximal hub and the distal hub. A drive gear including a plurality of threads disposed around the drive gear and including a proximal portion extending therefrom, configured to engage and mate with the corresponding plurality of teeth of the proximal and distal hubs, so that rotation thereof translates the proximal and distal hubs relative to each other and operates the end effector assembly. A drive gear, A drive input section including a drive input shaft having an input gear configured to fit and engage with a drive gear such that rotation of the drive input shaft rotates the drive gear accordingly, the drive input shaft including a mechanical contact surface disposed around it, the drive input section, A thumbwheel having at least a portion exposed outside the housing for external operation thereof, the thumbwheel including a corresponding mechanical contact surface disposed around its inner circumference, the mechanical contact surface of the drive input shaft being configured to fit and engage with the corresponding mechanical contact surface of the thumbwheel during selective translation of the thumbwheel, the thumbwheel being selectively translatable between a first disengaged position spaced from the mechanical contact surface disposed on the drive input shaft and a second engaged position in which the thumbwheel is fitted and engaged with the drive input shaft to enable manual operation of the end effector assembly, a thumbwheel, comprising a robotic surgical instrument. (Item 9) The robotic surgical instrument according to the above item, wherein the thumbwheel is biased at the disengaged position. (Item 10) Translating the thumbwheel along the drive input shaft and correspondingly rotating the thumbwheel rotates the drive input shaft and the drive gear, thereby translating the proximal hub relative to the distal hub to operate the end effector assembly, the robotic surgical instrument according to any one of the above items. (Item 11) The robotic surgical instrument according to any one of the above items, wherein translation of the proximal hub relative to the distal hub moves the drive rod to operate the end effector assembly. (Item 12) The robotic surgical instrument according to any one of the above items, wherein the end effector assembly includes a pair of first and second jaw members, and at least one of the jaw members is movable relative to the other of the jaw members. (Item 13) The drive input shaft is configured to engage with a plurality of corresponding teeth disposed along the inner peripheral surface of the cam wheel during selective translation of the cam wheel, and includes a plurality of castellations defined therearound, the robotic surgical instrument according to any one of the above items. (Item 14) The cam wheel is disposed distally of the spring compression assembly, the robotic surgical instrument according to any one of the above items. (Item 15) Movement of the cam wheel causes the plurality of teeth to engage distally with the corresponding plurality of castellations defined around the drive input shaft, the robotic surgical instrument according to any one of the above items. (Abstract) The robotic surgical instrument includes a housing having a shaft extending therefrom. The spring compression assembly is supported within the housing and configured to secure a drive rod disposed therethrough, and includes a proximal hub having teeth, a distal hub spaced from the proximal hub and having teeth, and a compression spring mounted between the proximal hub and the distal hub. The drive gear includes a proximal portion having threads disposed therearound configured to extend therefrom and engage the teeth of the proximal and distal hubs, rotation of which translates the hubs relative to each other to actuate an end effector assembly. A cam wheel is included having a portion exposed outside the housing for its external operation. The cam wheel is selectively positionable between a disengaged position spaced from the drive gear and an engaged position for mating engagement with the drive gear.

Brief Description of the Drawings

[0015] Various aspects and features of the present disclosure are described below in this specification with reference to the drawings.

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DETAILED DESCRIPTION OF THE INVENTION

[0016] Referring to FIGS. 1-2C, a surgical instrument 10 provided in accordance with the present 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 an actuation assembly 100 disposed within the housing 20 and operably associated with the shaft 30 and the end effector assembly 40. The instrument 10 is described herein in detail as an articulating electrosurgical grasper configured to be used with a robotic surgical system, such as robotic surgical system 500 (FIG. 3). However, the aspects and features of the instrument 10 provided in accordance with the present disclosure, as detailed below, are equally applicable to be used with other suitable surgical instruments and / or other suitable surgical systems.

[0017] The housing 20 of the instrument 10 includes a first body portion 22a and a second body portion 22b, and a proximal face plate 24 that cooperates to surround the actuation assembly 100 within the housing. The proximal face plate 24 includes an opening defined therein through which the input portions 110-140 of the actuation assembly 100 extend. A pair of latch levers 26 (only one is shown in FIG. 1) extend outwardly from both sides of the housing 20 and enable releasable engagement between the housing 20 and a robotic arm of a surgical system, such as robotic surgical system 500 (FIG. 3). An opening 28 defined through the housing 20 allows a thumb wheel 440 to extend therethrough, enabling manual operation of the thumb wheel 440 from outside the housing 20 to allow manual opening and closing of the end effector assembly 40.

[0018] The shaft 30 of the instrument 10 includes a distal segment 32, a proximal segment 34, and a kinematic section 36 disposed between the distal segment 32 and the proximal segment 34. The kinematic section 36 includes one or more kinematic components 37, such as links, joints, etc. A plurality of kinematic cables 38, such as four kinematic cables or other suitable actuators, extend through the kinematic section 36. More specifically, the kinematic cable 38 is operably connected to the distal segment 32 of the shaft 30 at its distal end portion, extends proximally from the distal segment 32 of the shaft 30 through the kinematic section 36 of the shaft 30 and the proximal segment 34 of the shaft 30, and into the housing 20. The kinematic cable 38 is operably connected to the kinematic assembly 200 of the actuation assembly 100 to enable selective kinematic movement (e.g., yaw and pitch kinematic movement) of the distal segment 32 (and thus the end effector assembly 40) about, for example, at least two kinematic axes with respect to the proximal segment 34 and the housing 20. The kinematic cables 38 are arranged in a generally rectangular configuration, although other suitable configurations are contemplated.

[0019] With respect to the kinematic movement of the end effector assembly 40 relative to the proximal segment 34 of the shaft 30, the actuation of the kinematic 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 the upper cable pair 38. For yaw kinematic 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 and opposite to the right cable pair 38.

[0020] The end effector assembly 40 includes a first jaw member 42 and a second jaw member 44, respectively. Each jaw member 42, 44 includes a proximal flange portion 43a, 45a and a distal body portion 43b, 45b, respectively. The distal body portions 43b, 45b define opposing tissue contact surfaces 46, 48, respectively. The proximal flange portions 43a, 45a are pivotally coupled to each other about a pivot 50 and are operatively coupled to each other via a cam slot assembly 52 that includes a cam pin slidably received within a cam slot defined within at least one of the proximal flange portions 43a, 45a of the jaw members 42, 44, enabling pivoting of the jaw member 42 relative to the jaw 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 an approaching position (e.g., a closed position of the end effector assembly 40) for gripping tissue between the tissue contact surfaces 46, 48. As an alternative to this one-sided configuration, a two-sided configuration can be provided, according to which both jaw members 42, 44 are drivable relative to each other and relative to the distal segment 32 of the shaft 30.

[0021] In some configurations, longitudinally extending knife channels (not shown) are defined through the tissue contact surfaces 46, 48 of the jaw members 42, 44, respectively. In such a configuration, a knife assembly 60 is provided that includes a proximal knife drive tube 62, a distal knife rod 64, an intermediate elongate collar 66, and a knife blade 68 (see FIGS. 26A, 26B, and 29A). The connector components 62-66 of the knife assembly 60 (see FIGS. 26A, 26B and 29A) extend from the housing 20 through the shaft 30 to the end effector assembly 40. The knife blade 68 (FIG. 29A) is disposed within the end effector assembly 40 between the jaw members 42, 44 and is provided to enable cutting of tissue gripped between the tissue contact surfaces 46, 48 of the jaw members 42, 44. The proximal knife tube 62 (FIGS. 4 and 26A-26B) is operably coupled at its proximal end to the knife drive assembly 300 of the actuation assembly 100 (FIGS. 2A-2B) to enable its selective actuation, and then reciprocate the knife blade 68 (FIG. 29A) between the jaw members 42, 44 to enable cutting of tissue gripped between the tissue contact surfaces 46, 48.

[0022] Continuing further with reference to FIGS. 1-2C, the drive rod 484 is operably coupled to the cam slot assembly 52 of the end effector assembly 40, for example by engaging its cam pin, such that longitudinal actuation of the drive rod 484 causes the jaw member 42 to pivot between a spaced-apart position and an approaching position relative to the jaw member 44. More specifically, biasing the drive rod 484 proximally pivots the jaw member 42 towards the approaching position relative to the jaw member 44, while biasing the drive rod 484 distally pivots the jaw member 42 towards the spaced-apart position relative to the jaw member 44. However, other suitable mechanisms and / or configurations for pivoting the jaw member 42 between the spaced-apart position and the approaching position in response to selective actuation of the drive rod 484 are contemplated. The drive rod 484 extends from the end effector assembly 40 through the shaft 30 into the housing 20, and the drive rod 484 is operably coupled to the jaw drive assembly 400 of the actuation assembly 100 (FIGS. 2A-2B) to enable selective actuation of the end effector assembly 40 to grip tissue therebetween and apply a closing force within an appropriate range of jaw closing forces.

[0023] The tissue contact surfaces 46, 48 of the jaw members 42, 44 are each at least partially formed of a conductive material and are energizable to different potentials to enable conduction of electrical energy through the tissue gripped therebetween. However, the tissue contact surfaces 46, 48 may alternatively be configured to supply any suitable energy, such as heat, microwaves, light, ultrasound, etc., through the tissue gripped therebetween for energy-based tissue treatment. The instrument 10 may include leads 99, contacts, and / or conductive components to define a conductive path (not shown) through the housing 20 and the shaft 30 to the end effector assembly 40 to supply energy, such as from an energy source (not shown), e.g., an electrosurgical generator, etc., to the tissue contact surfaces 46, 48 of the jaw members 42, 44 for treating, e.g., sealing, the tissue gripped between the tissue contact surfaces 46, 48.

[0024] As described above, the actuating assembly 100 is disposed within the housing 20 and includes the articulation assembly 200, the knife drive assembly 300, and the jaw drive assembly 400. The articulation assembly 200 is operably coupled between the first input portion 110 and the second input portion 120 of the actuating assembly 100 and the articulation cable 38 (FIG. 1), respectively. Thus, when receiving appropriate inputs to the first input portion 110 and the second input portion 120, the articulation assembly 200 operates the cable 38 (FIGS. 1 and 5) to articulate the end effector assembly 40 in a desired direction, for example, pitch and / or yaw the end effector assembly 40. The knife drive assembly 300 is operably coupled between the third input portion 130 of the actuating assembly 100 and the knife tube 62 (FIGS. 26A-26B). Thus, when receiving an appropriate rotational input to the third input portion 130, the knife drive assembly 300 operates the knife tube 62 to reciprocate the knife blade 68 (FIG. 29A) between the jaw members 42, 44 to cut the tissue grasped between the tissue contact surfaces 46, 48. The jaw drive assembly 400 is operably coupled between the fourth input portion 140 of the actuating assembly 100 and the drive rod 484. Thus, when receiving an appropriate rotational input to the fourth input portion 140, the jaw drive assembly 400 pivots the jaw members 42, 44 between a spaced-apart position and an approaching position to grasp the tissue between the jaw members and apply a closing force within a suitable range of closing forces.

[0025] The actuation assembly 100 is configured to operatively connect with the robotic surgical system 500 (FIG. 3) when the instrument 10 is attached to the robotic surgical system 500 (FIG. 3), enabling robotic operation of the actuation assembly 100 and providing the above functions. That is, the robotic surgical system 500 (FIG. 3) selectively provides inputs to the input portions 110-140 of the actuation assembly 100 to articulate the end effector assembly 40, grasp tissue between the jaw members 42, 44, and / or cut tissue grasped between the jaw members 42, 44. However, it is also contemplated that the actuation assembly 100 may be configured to connect with any other suitable surgical system, such as a manual surgical handle, an electric surgical handle, etc. For the purposes of this specification, the robotic surgical system 500 (FIG. 3) will be described schematically.

[0026] Referring to FIG. 3, the robotic surgical system 500 is configured for use in accordance with the present disclosure. Aspects and features of the robotic surgical system 500 that are not relevant to the understanding of the present disclosure are omitted to avoid obscuring the aspects and features of the present disclosure with unnecessary detail.

[0027] The robotic surgical system 500 generally includes a plurality of robotic arms 502, 503, a control device 504, and an operation console 505 coupled to the control device 504. The operation console 505 may include a display device 506 that can be set up to display three-dimensional images in particular, and manual input devices 507, 508 by which a person, such as a surgeon, can remotely operate the robotic arms 502, 503 in a first operation mode. The robotic surgical system 500 may be configured for use on a patient 513 lying on a patient table 512 to be treated in a minimally invasive manner. The robotic surgical system 500 can further include, in particular, a database 514 coupled to the control device 504, in which, for example, preoperative data and / or anatomical diagrams from the patient 513 are stored.

[0028] Each of the robotic arms 502, 503 may include a plurality of members connected via joints and a mounted device, such as a surgical tool "ST". One or more of the surgical tools "ST" may be the instrument 5 (FIG. 1), and thus provide such functionality in the robotic surgical system 500.

[0029] The robotic arms 502, 503 may be driven by an electric device, such as a motor, connected to a control device 504. The control device 504, such as a computer, may be configured to operate the motor, particularly by a computer program, so that the robotic arms 502, 503, and thus their mounted surgical tools "ST", each perform a desired movement and / or function according to a corresponding input from the manual input devices 507, 508. The control device 504 may be configured to adjust the movement of the robotic arms 502, 503 and / or the motor.

[0030] Referring generally to FIGS. 1, 2A-2C, 4, and 5, the articulation assembly 200 of the actuation assembly 100 includes a lead screw subassembly 210, a first gear subassembly 230, a second gear subassembly 250, a third gear subassembly 270, and first and second input shafts 292, 294. The articulation assembly 200 is described in detail herein as including a plurality of gears, but such gear components may be replaced or supplemented by the use of belts instead of directly meshing gears without departing from the present disclosure. Further, multiple gears (and / or belts) may be provided instead of a single gear (and / or belt) to provide a desired amplification or attenuation effect.

[0031] The parent screw sub - assembly 210 of the actuation assembly 100 includes four parent screws 212 arranged to define a generally square configuration in which the diagonally - opposed parent screws 212 define opposite screw - pitch directions. Each parent screw 212 includes a collar 214 threaded therearound such that rotation of the parent screw 212 causes translational movement of the collar 214 longitudinally along the corresponding collar 214. Each collar 214 then secures, for example, by crimping or other suitable engagement (mechanical fixation, adhesion, welding, etc.), the proximal end portion of one of the articulation cables 38 therein. Thus, translation of the collar 214 in the distal direction loosens the corresponding articulation cable 38 by pushing the corresponding articulation cable 38 in the distal direction, while translation of the collar 214 in the proximal direction tensions the corresponding articulation cable 38 by pulling the corresponding articulation cable 38 in the proximal direction.

[0032] The parent screw sub - assembly 210 further includes a distal plate 220 that includes four bushings 222, each of which rotatably holds the distal end portion of one of the four parent screws 212. The proximal end portions of the parent screws 212 define a keyed, for example, semi - circular input portion such that a rotational input to the proximal end portion rotates the parent screw 212. In some configurations, the proximal end portion of the shaft 30 engages (either directly or indirectly) fixedly with the distal plate 220.

[0033] The first gear sub - assembly 230 includes a distal housing body 232 and a proximal housing body 234 that cooperate to operably support a first pair of diagonally - opposed gears mounted to a keyed output such that rotation of one of the gears rotates the corresponding keyed output portion. The proximal end portions of a pair of diagonally - opposed parent screws 212 of the parent screw sub - assembly 210 couple with the corresponding keyed output portions of the first gear sub - assembly 230, thereby rotatably coupling each of the gears of the first gear sub - assembly 230 with one of the parent screws 212 of a pair of diagonally - opposed parent screws 212 such that rotation of one of the gears rotates the corresponding parent screw 212.

[0034] The second gear sub-assembly 250 includes a distal housing body 252 and a proximal housing body 254 that cooperate to operably support a second pair of diagonally opposed gears mounted to the keyed output portion, a central compound gear, and a first coupling gear mounted to a first coupling shaft. The first coupling gear 264 is disposed in meshing engagement with the proximal gear of the central compound gear.

[0035] A first diagonal pair of the articulation cables 38 is pre-tensioned before the second gear sub-assembly 250 engages the first gear sub-assembly 230. Upon this engagement, the keyed output portion 250 of the second gear sub-assembly 250 rotatably couples proximal end portions of a second pair of diagonally opposed lead screws 212, such that rotation of one of the gears rotates the corresponding lead screw 212, rotatably coupling each of the gears of the second gear sub-assembly 250 to one of the lead screws 212 of the second pair of diagonally opposed lead screws 212. Engagement of the second gear sub-assembly 250 with the first gear sub-assembly 230 also disposes the distal gear of the central compound gear in meshing engagement between the diagonally opposed gears of the first gear sub-assembly 230, thereby coupling the diagonally opposed gears to each other, coupling the lead screws 212 of the first pair of diagonally opposed lead screws 212 to each other, and locking the pre-tension in the first pair of articulation cables 38.

[0036] The third gear sub - assembly 270 includes a distal housing body 272 and a proximal housing body 274 that operably support a central compound gear and a second coupling gear mounted on a second coupling shaft. The second coupling shaft includes a second coupling gear mounted thereon and has a proximal end portion that defines a keyway. Prior to engaging the third gear sub - assembly 270 with the second gear sub - assembly 250, a pre - tension is applied to a second diagonal pair of articulation cables 38. When the pre - tension threshold of the second diagonal pair of articulation cables 38 is reached, the third gear sub - assembly 270 engages with the second gear sub - assembly 250, and the distal gear of the central compound gear of the third gear sub - assembly 270 meshes with and is disposed between the gears that oppose each other on the second diagonal of the second gear sub - assembly 250, coupling the diagonally - opposing gears to each other, thereby coupling the gears that oppose each other on the second diagonal, thereby coupling a pair of parent screws 212 that oppose each other on the second diagonal, and locking the pre - tension of the second pair of articulation cables 38.

[0037] As detailed above, with the first, second, and third gear sub-assemblies 230, 250, 270 and the lead screw sub-assembly 210 each assembled to one another, the input shafts 292, 294 can be connected between the input portions 110, 120 and the keyed output portions of the first and second gear sub-assemblies 230, 240, respectively. Thus, in use, the rotational input provided to the input portions 110, 120 can be utilized to move the color 214 around the diagonal lead screw 212 in a pair. Depending on the direction of the rotational input provided to the input portions 110, 120 and whether the input portions for the pair are the same or opposite, articulation motion of the pitch (in either direction), yaw articulation motion (in either direction), and / or any combination thereof can be achieved. The articulation assembly 200 is described in detail in U.S. Patent Application No. 16 / 395,748, filed on April 26, 2019, entitled "ARTICULATION ASSEMBLY FOR A SURGICAL INSTRUMENT SUCH AS FOR USE IN A ROBOTIC SURGICAL SYSTEM AND METHODS OF ASSEMBLING THE SAME".

[0038] Continuing to refer to FIGS. 1, 2A-2C, 4, and 5, the knife drive assembly 300 includes an input shaft 310, an input gear 320 engaged with the input shaft 310, a male screw disposed to mesh with the input gear 320, a central gear 330 defining a female screw, and a lead screw 340 engaged with the female screw thereof and extending through the central gear 330. As a result of this configuration, the rotational input provided to the third input portion 130 rotates the input shaft 310, thereby rotating the input gear 320, which in turn rotates the central gear 330, resulting in the translation of the lead screw 340. Since the lead screw 340 is fixedly engaged around the proximal end portion of the knife tube 62, the translation of the lead screw 340 translates the knife tube 62, for example, thereby translating the knife blade 68 (FIG. 29A) between the jaw members 42, 44 (FIG. 1) to cut the tissue grasped therebetween. The lead screw 340 and the knife tube 62 are coaxially disposed about the drive rod 484.

[0039] The Joe drive assembly 400 includes an input shaft 410 operably coupled to a fourth input portion 140 at its proximal end portion, an input gear 420 fixedly engaged with the input shaft 410 at its distal end portion, a drive gear 430 disposed in meshing engagement with the input gear 420, a thumb wheel 440 disposed in fitting engagement with the drive gear 430, a lead screw 434 fixedly engaged with the drive gear 430, for example integrally formed, and a spring force assembly 450 operably coupling the lead screw 434 to a drive rod 484. More specifically, the spring force assembly 450 includes a proximal hub 452 engaging the proximal end portion of the drive rod 484, a distal hub 454 threadedly engaged around the lead screw 434, and a compression spring 456 disposed between the proximal and distal hubs 452, 454, respectively. As a result of this configuration, in response to a rotational input to an input portion, for example the fourth input portion 140, for closing the end effector assembly 40 or a manual input to the rotational wheel 440, the drive shaft 410 is rotated, thereby rotating the input gear 420, and then rotating the drive gear 430, so that the distal hub 454 is translated proximally toward the proximal hub 452. Initially, when the force resisting the approach of the Joe members 42, 44 is less than a threshold value corresponding to the spring value of the compression spring 456, the closing force applied by the Joe members 42, 44 is relatively low, and thus, by biasing the distal hub 454 proximally with respect to the compression spring 456, the compression spring 456 is biased proximally, and then the drive rod 484 is biased proximally to pivot the Joe member 42 from a spaced position toward an approaching position with respect to the Joe member 44 to grip tissue between the Joe members. When the Joe members 42, 44 approach further and grip tissue between the Joe members, the force resisting the approach of the Joe members 42, 44, for example the force with which the tissue resists compression, may reach the threshold value, and thus, the closing force applied by the Joe members 42, 44 may reach the corresponding threshold value. For example, about 3 kg / cm 2 ~ about 16 kg / cm 2Within a range of closing forces such as, to hold the closing force applied by the jaw members 42, 44, despite further rotational input to the fourth input portion 140, further application of a closing force by the jaw members 42, 44 beyond this point is prevented. More specifically, when a threshold value is reached, further rotational input to the fourth input portion 140 rotates the drive shaft 410, the input gear 420, and the drive gear 430 to translate the distal hub 454 further proximally into the compression spring 456. However, rather than the compression spring 456 biasing the proximal hub 452 to continue to move the jaw members 42, 44 closer proximally and increasing the closing force applied between the jaw members, the compression spring 456 is compressed, allowing the proximal hub 452, and thus the drive rod 484, to remain in place despite the continued movement of the distal hub 454, and thus preventing the application of additional closing force between the jaw member 42 and the jaw member 44. With an appropriate closing force, when the tissue is grasped between the jaw members 42, 44, energy can be supplied to the jaw members 42, 44 to effect treatment, such as by sealing the tissue. Thereafter, a knife 68 (FIG. 29A) can be advanced between the jaw members 42, 44 to cut the treated tissue.

[0040] Turning to FIG. 6, in conjunction with FIG. 1, as described above, the shaft 30 extends distally from the housing 20 and includes a distal segment 32, a proximal segment 34, and an articulation section 36. In some configurations, as also described above, the proximal end portion of the proximal segment 34 of the shaft 30 extends into the housing 20 and engages (either directly or indirectly) fixedly with the distal plate 220 of the articulation assembly 200 (see FIG. 2A) within the housing 20. The articulation cable 38 (FIGS. 1, 4, and 5), the knife tube 62 (FIGS. 4 and 5), and the conductive structure (e.g., the lead wire 99 (FIG. 1)) extend through the proximal segment 34 of the shaft 30 to the articulation section 36, the distal segment 32, or the end effector assembly 40, enabling articulation of the end effector assembly 40 in pitch and yaw directions and enabling operation of the end effector assembly 40 for grasping, treating, and / or cutting tissue. To support these components extending through the shaft 30 and to maintain proper positioning, spacing, and / or orientation of these components extending through the shaft 30, one or more internal structures 39 are disposed or formed within the shaft 30. The one or more internal structures 39 may include, for example, any combination of one or more of supports, spacers, guides, bushings, etc., and may extend continuously or intermittently along a part or all of the shaft 30.

[0041] Referring generally to FIGS. 1-6, during use of the instrument 10, fluid (including blood, other body fluids, surgical fluids, etc., including fluid carrying tissue, surgical debris, etc.) from the surgical site can enter the instrument 10 through the end effector assembly 40, through the articulation section 36 of the shaft 30, and / or through other locations, and move proximally towards or into the housing 20 within and / or around the shaft 30. To protect capital equipment such as the robotic arm of a robotic surgical system, e.g., the robotic surgical system 500 (FIG. 3) on which the instrument 10 is mounted (and / or for other purposes such as to facilitate cleaning of all or part of the instrument 10 in preparation for reuse, etc.), the present disclosure provides various different seal configurations (one-component seals, multi-component seals, multiple seals, seal assemblies including one or more seals, and one or more support / holding components) disposed at various different locations along the instrument 10 to inhibit the fluid moving proximally from contaminating the robotic arm (and / or a portion of the instrument 10).

[0042] More specifically, one or more seals can be disposed at one or more of the following locations: location "A" at the proximal end of the shaft 30 within or adjacent to the housing 20, location "B" at one or more positions along a portion of the proximal segment 34 of the shaft 30, location "C" at or near the proximal end portion of the knife assembly 60, the knife drive assembly 300, and / or the jaw drive assembly 400, location "D" at or near the distal end portion of the knife assembly 60 and / or the jaw drive assembly 400, and / or location "E" at or near the articulation section 36 of the shaft 30. Further, the seals are used at one location, as detailed herein, but it is contemplated that these seals can be used at any of the other identified locations or other suitable locations to the extent practicable. Similarly, any suitable combination of seals at one or more of the identified locations and / or other suitable locations can be provided.

[0043] Referring to FIG. 7, a seal configuration 700 provided in accordance with the present disclosure is shown to be used at location "A" (FIGS. 1, 2A-2C, and 6). More specifically, the seal configuration 700 includes an enlarged proximal end portion 702 of the proximal segment 34 of the shaft 30 and a seal 704 disposed therein. The enlarged proximal end portion 702 is disposed within the housing 20 and is attached, for example, by welding or other means, to the distal plate 220 of the parent screw subassembly 210 (see FIGS. 2A-2C). The enlarged proximal end portion 702 defines a larger inner diameter as compared to the body of the proximal segment 34 of the shaft 30. The relatively large inner diameter of the enlarged proximal end portion 702 facilitates the manufacture of the seal 704 and / or the assembly of the seal 704 within the enlarged proximal end portion 702. Further, during assembly, while the distal plate 220 inhibits substantial proximal movement of the seal 704, the smaller diameter body of the proximal segment 34 of the shaft 30 substantially inhibits proximal movement of the seal 704, so that the seal 704 is substantially retained in position within the enlarged proximal end portion 702 of the proximal segment 34 of the shaft 30. The seal 704 may be formed as a solid piece of material, such as an elastomeric material, as a single piece of material inserted into the enlarged proximal end portion 702, or as multiple pieces of material joined together before or during insertion into the enlarged proximal end portion 702. In some configurations, the seal 704 may include a grease-coated or lubricated plug to facilitate seal insertion and formation. Grease or other lubricants may similarly be utilized to facilitate sealing in any of the other configurations detailed herein. The seal 704 may alternatively be a semi-solid material, such as a gel, or a material that is injected into the enlarged proximal end portion 702 in a certain form, state, or phase, before transitioning to another form, state, or phase, such as a foam, injectable silicone, etc. The above combinations may also be utilized.Regardless of the specific configuration of the seal 704, the seal 704 serves to establish a seal around the actuating component 706 extending within and through the enlarged proximal end portion 702, such as the articulation cable 38 (Figs. 1, 4, and 5), the knife tube 62 (Figs. 4 and 5), and the lead wire 99 (Fig. 1). Thus, the seal 704 functions to allow the movement of the actuating component 706 extending therethrough while suppressing the passage of fluid in the proximal direction across the seal 704. Other suitable configurations of the seal 704, such as those detailed below, are also contemplated.

[0044] Referring to FIG. 8, it is shown that another seal configuration 800 provided in accordance with the present disclosure is being used at location "A" (Figs. 1, 2A - 2C, and 6). More specifically, the seal configuration 800 includes a connector shaft 802 that includes a seal 804 disposed therein. The connector shaft 802 is disposed within the housing 20 and is fixed, for example, by welding or other means, to the distal plate 220 of the parent screw sub - assembly 210 (see Figs. 2A - 2C) and the proximal segment 34 of the shaft 30, thereby fixing the proximal segment 34 of the shaft 30 to the distal plate 220. The connector shaft 802 defines a larger inner diameter as compared to the proximal segment 34 of the shaft 30. The relatively large inner diameter of the connector shaft 802 facilitates the manufacture of the seal 804 and / or the assembly of the seal 704 within the connector shaft 802. Further, during assembly, the distal plate 220 inhibits substantial proximal movement of the seal 804 and the smaller - diameter proximal segment 34 of the shaft 30 inhibits substantial distal movement of the seal 804, so that the seal 804 is substantially held in place within the connector shaft 802 of the proximal segment 34 of the shaft 30. The seal 804 can be formed, inserted, assembled, and / or configured in the same manner as detailed above with respect to the seal 704 (Fig. 7) or in any other suitable manner.

[0045] Figures 9A and 9B show yet another seal configuration 900 provided in accordance with the present disclosure for use at location "A" (Figs. 1, 2A - 2C, and 6) or any other suitable location. More specifically, seal configuration 900 includes an enlarged proximal end portion 902 of the proximal segment 34 of shaft 30 and a two - component seal 904 disposed therein. The enlarged proximal end portion 902 is disposed within housing 20 (see Figs. 4 and 5) and can be attached and fixed, for example, by welding or other means, to the distal plate 220 of the parent screw sub - assembly 210 (see Figs. 2A - 2C). The enlarged proximal end portion 902 defines a larger inner diameter compared to the body of the proximal segment 34 of shaft 30. The relatively large inner diameter of the enlarged proximal end portion 902 facilitates the manufacture of seal 904 and / or the assembly of seal 904 within the enlarged proximal end portion 902. The enlarged proximal end portion 902 includes one or more retaining slots 908 defined therein, each defining an L - shaped configuration. Two diametrically opposed L - shaped retaining slots 908 are shown in Fig. 9B, although other numbers and / or configurations of retaining slots 908, such as T - shaped slots, are contemplated.

[0046] The two - component seal 904 includes an outer collar 910 and an inner plug 920. The outer collar 910 includes one or more retaining protrusions 912 extending radially outward therefrom, each defining an L - shaped configuration. Two diametrically opposed L - shaped protrusions 912 are shown in Fig. 9B, although other numbers and / or configurations of retaining protrusions 912 complementary to the retaining slots 908 are also contemplated. The retaining protrusions 912 are configured to be received within the retaining slots 908 and seat the outer collar 910 within the enlarged proximal end portion 902 in a sealed relationship with respect to its inner annular surface. The outer collar 910 further includes an irregular, e.g., non - circular lumen 914 defined therethrough.

[0047] The inner plug 920 of the seal 904 is configured to be complementarily received within the irregular lumen 914 of the outer collar 910. The outer collar 910 and the inner plug 920, together with the inner plug 920 received within the irregular lumen 914 of the outer collar 910, define complementary features 922, such as protrusions and recesses, and / or other suitable features or configurations such that the inner plug 920 is fixedly retained within the outer collar 910 and forms a seal therewith (despite the defined passageway therethrough). The outer collar 910 and the inner plug 920 can also cooperate to define one or more radial lumens 924 therebetween, and / or the inner plug 920 can define a central lumen 926. The lumens 924, 926 are configured to establish a seal with operating components extending therethrough, such as the articulation cable 38 (Figs. 1, 4, and 5), the knife tube 62 (Figs. 4 and 5), and the lead wire 99 (Fig. 1).

[0048] The outer collar 910 and the inner plug 920 of the seal 904 may be formed from the same or different materials and are configured to cooperate to establish a seal around and through the operating components extending within and through the enlarged proximal end portion 902. Thus, the seal 904 functions to allow the operation of the operating components extending therethrough while inhibiting the passage of fluid in the proximal direction across the seal 904.

[0049] Turning to FIGS. 10 - 13, various seal configurations 1000, 1100, 1200, 1300 provided in accordance with the present disclosure are shown. The seal configurations 1000, 1100, 1200, 1300 can be utilized with or without an enlarged proximal end portion of the proximal segment 34 of the shaft 30, and include retention features associated with, on, within, or otherwise related to the proximal end portions 1002, 1102, 1202, 1302 of the proximal segment 34 of the shaft 30 to facilitate a sealing relationship with the corresponding seals 1004, 1104, 1204, 1304 and to maintain them in a substantially fixed position within the proximal segment 34 of the shaft 30. The seal configurations 1000, 1100, 1200, 1300 may be replicated and / or used in combination with one another, and are described for use at location "A", but alternatively or additionally, within a non - conflicting scope, can be utilized at location "B" and / or any other suitable location (see FIGS. 1, 2A - 2C, and 6).

[0050] The seal configuration 1000 shown in FIG. 10 includes a lock ring 1030 having a proximal flange 1032 configured to be adjacent to the proximal side of the distal plate 220 of the parent screw sub - assembly 210 (see FIGS. 2A - 2C), and a distal body 1034 configured to extend, for example, in a press - fit manner through the distal plate 220 to the proximal end portion 1002 of the proximal segment 34 of the shaft 30. The distal body 1034 reduces the effective inner diameter of the proximal end portion 1002 and thus inhibits the proximal movement of the seal 1004. The seal 1004 may be similar to the seal 700 (FIG. 7) or any other suitable seal.

[0051] As shown in FIG. 11, the seal configuration 1100 includes a plurality of protrusions 1106 that are disposed annularly around the seal 1104 and extend radially outward from the seal 1104, and a plurality of corresponding openings 1108 that are defined annularly around the proximal end portion 1102 of the proximal segment 34 of the shaft 30. However, it is also contemplated that both the seal 1104 and the proximal end portion 1102 may have opposite configurations or protrusions and openings. When the seal 1104 is inserted into the proximal end portion 1102, the protrusions 1106 are compressed radially inwardly, allowing the seal 1104 to be inserted into the proximal end portion 1102. When the protrusions 1106 are aligned with the openings 1108, the protrusions 1106 are elastically returned and extend through the openings 1108, thereby holding the seal 1104 in position within the proximal end portion 1102. The seal 1104 may otherwise be similar to the seal 700 (FIG. 7) or any other suitable seal.

[0052] The seal configuration 1200 shown in FIG. 12 includes one or more annular ribs 1206 that extend radially inwardly within the proximal end portion 1202 of the proximal segment 34 of the shaft 30. The ribs 1206 can be formed by indenting the outer surface of the proximal end portion 1202, by adding additional material within the proximal end portion 1202, or in any other suitable manner. Further, the ribs 1206 may be disposed proximal, distal, or on both sides of the seal 1204. When the seal 1204 is inserted into the proximal end portion 1202, the seal 1204 is compressed radially inwardly, allowing the seal 1204 to pass through the ribs 1206 and reach a more distal position of the ribs 1206. When the seal 1204 passes through the ribs 1206, the seal 1204 is elastically returned and seals against the inner surface proximal end portion 1202. The reduced effective diameter of the proximal end portion 1202 provided by the ribs 1206 inhibits the seal 1204 from moving proximally. The seal 1204 may be similar to the seal 700 (FIG. 7) or any other suitable seal.

[0053] As shown in FIG. 13, seal configuration 1300 is the same as seal configuration 1200 (FIG. 12), except that instead of ribs that inhibit proximal movement of the seal, it includes a plurality of radially and axially disposed protrusions 1306 that project radially inward to the interior of proximal end portion 1302, reducing its effective inner diameter.

[0054] Turning to FIG. 14, yet another seal configuration 1400 according to the present disclosure is provided for use at location “A”, location “C”, locations therebetween, or any other suitable location (see FIGS. 1, 2A - 2C, and 6). Seal configuration 1400 includes a seal 1404 and a lock plate 1440. Seal 1404 includes a proximal flange 1412 configured to be proximally adjacent to distal plate 220 and a distal body 1414 configured to extend through distal plate 220 to proximal end portion 1402 of proximal segment 34 of shaft 30. Seal 1404 may include one or more lumens 1416 that extend completely therethrough, one or more openings 1418 that extend through proximal flange 1412, and / or one or more channels 1420 that extend along distal body 1414, which individually or cooperatively engage sealingly with actuating components extending therethrough, such as articulation cable 38, knife tube 62, and lead wire 99 (FIG. 1). Slits defined within proximal flange 1412 and / or distal body 1414 provide a sealable connection between lumen 1416, opening 1418, and / or the outer circumferential surface of proximal flange 1412 and / or distal body 1414 to facilitate insertion and engagement of actuating components therein. Such slits may be used in the same manner for similar purposes in other sealing configurations detailed herein.

[0055] The lock plate 1440 includes a body 1442 that defines one or more openings 1444 that are aligned with the lumen 1416, the opening 1418, and the channel 1420 of the seal 1404 to allow actuating components, such as the articulation cable 38, the knife tube 62, and the lead wire 99 (FIG. 1), to pass therethrough. The lock plate 1440 is configured to at least partially compress the proximal flange 1412 between the lock plate 1440 and the distal plate 220 adjacent proximally to the proximal flange 1412 of the seal 1404, thereby establishing a seal around the distal plate 220 and the passage extending through the shaft 30. Alternatively or additionally, any gaps can be filled with grease or other suitable material to establish a seal. The lock plate 1440 is fixed in a predetermined position relative to the distal plate 220, thereby maintaining the seal by screwing the lock plate 1440 onto the distal plate 220 and / or by using any other suitable fastener or engagement feature. The distal body 1414 of the seal 1404 extends additionally or alternatively through the distal plate 220 into the proximal end portion 1402 of the proximal segment 34 of the shaft 30 that is in sealing relation with the inner surface of the proximal end portion 1402 to establish a seal therein.

[0056] Referring to FIGS. 15-17A, further configurations 1500, 1600, 1700 are provided in accordance with the present disclosure configured for use at location "A" and / or any other suitable location (see FIGS. 1, 2A-2C, and 6). Each of the configurations 1500, 1600, 1700 may include one or more portions 1501, 1601, 1701 of the housing 20 that are sealed, e.g., via a bulkhead 1503, 1603 or other suitable structure or combination of structures, to define a sealed volume within the housing 20, and in some configurations, the entire interior of the housing 20 defines a sealed volume. The portions 1501, 1601, 1701 are shown at the distal end of the housing 20, although additional and / or alternative locations are contemplated.

[0057] Regarding the configuration 1500 of FIG. 15, one or more openings 1506 or other openings are defined through the proximal end portion 1502 of the proximal segment 34 of the shaft 30 that is in fluid communication with the sealed volume defined by the portion 1501. Thus, fluid moving proximally through the proximal segment 34 of the shaft 30 into the housing 20 can exit the proximal end portion 1502 and enter the portion 1501 via the opening 1506. Alternatively or additionally, a drain tube 1550 connected to one of the openings 1506 and / or in fluid communication with the portion 1501 of the housing 20 may be provided to allow for drainage of such fluid. In such a configuration, a joint or other suitable connection (not shown) may be provided to the housing 20 to allow for connection of a drain line (not shown).

[0058] The configuration 1600 shown in FIG. 16 similarly includes one or more openings 1606 or other openings are defined through the proximal end portion 1602 of the proximal segment 34 of the shaft 30 that is in fluid communication with the sealed volume defined by the portion 1601. The configuration 1600 differs from the configuration 1500 (FIG. 15) in that rather than providing a drain tube, the configuration 1600 includes one or more sponges 1660 or other suitable fluid-absorbing material disposed within the portion 1601 to absorb fluid entering the portion 1601 via the openings 1606.

[0059] FIG. 17A shows a configuration 1700 in which the portion 1701 of the housing 20 or the entire housing 20 is filled with an injectable material 1770, such as a sealant material and / or an absorbent material, to form a seal against passing fluid and / or absorb liquid. The injectable material 1770 may be a foam, gel, grease, phase change material, etc. As shown in FIG. 17B, in other configurations, an opening 1772 defined within the shaft 30 (or other component) is provided to allow injection of the injectable material 1770 to provide additional seal and / or absorption regions, for example, at locations "B" or "E" (see FIGS. 1, 2A-2C, and 6), for example, to seal the shaft 30 and components extending therethrough.

[0060] Turning to FIG. 18, another seal 1804 provided in accordance with the present disclosure is configured for use at locations "A", "B", "E" (FIGS. 1, 2A-2C, and 6) and / or any other suitable location. The seal 1804 includes a pair of wedge seal members 1882, 1884. The wedge seal members 1882, 1884 can define complementary engagement features 1886, such as interlocking tabs, protrusions, and apertures, configured to engage with each other to fix the wedge seal members 1882, 1884 to each other. Each wedge seal member 1882, 1884 further defines one or more lumens 1888 that extend therethrough and are aligned with each other when the wedge seal members 1882, 1884 engage. When the wedge seal members 1882, 1884 engage with each other, the seal 1804 may define a rectangular cross-sectional configuration, a circular cross-sectional configuration, or any other suitable configuration that enables the seal of the seal 1804, for example, within a region within the shaft 30 (FIG. 1). The lumens 1888 are configured to receive one or more actuating components, such as the articulation cable 38 (FIGS. 1, 4, and 5), the knife tube 62 (FIGS. 4 and 5), and the lead wire 99 (FIG. 1), while allowing their operation and being in a sealing relationship therewith.

[0061] When used with respect to the shaft 30 (FIG. 1), for example, the wedge seal member 1882 is inserted in a first direction, such as the distal direction, through a portion of the shaft 30 and around one or more actuating components, while the wedge seal member 1884 is inserted through a portion of the shaft 30 and around one or more actuating components in a second opposite direction, such as the proximal direction, until the wedge seal members 1882, 1884 contact and engage with each other via the complementary engagement features 1886, thereby forming a seal within the shaft 30 and around approximately one or more actuating components. The wedge seal members 1882, 1884 can be formed from the same or different materials, including an elastomeric material or other suitable material.

[0062] Referring to FIG. 19, another seal 1904 provided in accordance with the present disclosure is configured to be used at locations “A”, “B”, “E” (FIGS. 1, 2A-2C, and 6), and / or any other suitable location. The seal 1904 includes a seal body 1920. The seal body 1920 is configured to establish a seal against an inner surface of a structure, such as an inner surface of the shaft 30 (FIG. 1). The seal body 1920 has one or more lumens 1922 extending therethrough. Each lumen 1922 defines a diameter greater than the diameter of an actuating component, such as an articulation cable 38 (FIGS. 1, 4, and 5), a knife tube 62 (FIGS. 4 and 5), and a lead wire 99 (FIG. 1), and is configured to pass therethrough. A plurality of duckbill seals 1924 extend from one or both sides of the seal body 1920, and each duckbill seal 1924 surrounds one end of the lumen 1922. The duckbill seal 1924 may be a zero-closure seal or an actuating component configured to pass therethrough, such as an articulation cable 38 (FIGS. 1, 4, and 5), a knife tube 62 (FIGS. 4 and 5), and a lead wire 99 (FIG. 1), may be closer to a smaller diameter. In this way, the seal body 1920 seals against an external structure, such as the shaft 30, while the duckbill seal 1924 seals around an internal structure, such as an actuating component. The duckbill seal 1924 can establish additional or alternative sealing around the actuating component when there is a pressure differential across the entire seal 1904, such as when the shaft 30 (FIG. 1) is inserted into a body cavity being insufflated.

[0063] Turning to FIG. 20, another seal 2004 provided is configured for use at locations “A”, “B”, “E” (FIGS. 1, 2A-2C, and 6) and / or any other suitable location and includes a compressible seal body 2006 captured between a pair of rigid plates 2008. The body 2006 and the plates 2008 cooperate to define a lumen 2010 therethrough and can allow the passage of operating components in a sealed relationship with the seal body 2006. During assembly, the seal body 2006 may be inserted around an external structure, such as a shaft 30, and / or an internal structure, such as one or more operating components, prior to positioning of the plates 2008. Next, the plates 2008 may be positioned on either side of the seal body 2006 and moved towards each other to compress the seal body 2006 in the shaft direction and urge the seal body 2006 to seal around the external structure and / or around the internal structure. The plates 2008 may be held in place via engagement with each other and / or with the external structure.

[0064] Referring to FIG. 21, yet another seal 2104 is configured for use at locations “A”, “B”, “E” (FIGS. 1, 2A-2C, and 6) and / or any other suitable location. The seal 2104 includes a plurality of seal components 2105 each disposed in a sealed and fixed relationship around an operating component, such as one of the articulating cables 38, for example via overmolding. The seal components 2105 function as wipers that cooperate to maintain a seal around an external structure, such as a shaft 30, and / or an internal structure, such as a knife tube 62, even when relative translation occurs between them.

[0065] Referring to FIG. 22, the absorbent and / or seal member 2204 provided in accordance with the present disclosure for use at locations "A", "B", "E" (FIGS. 1, 2A-2C, and 6) and / or any other suitable location is initially disposed in a contracted configuration. The member 2204 is disposed, for example, around an internal operating component such as the knife tube 62, and may define a slit 2206, for example, disposed sealingly and enabling the lateral insertion of the member 2204 around the knife tube 62. The member 2204 is configured to be positioned within the shaft 30 (or other suitable outer component), is initially disposed in a non-sealing relationship therewith, and occupies a relatively small volume within the shaft 30. The slit 2206 may be a zero-closure slit. When fluid contacts and is absorbed by the member 2204, the member 2204 expands to fill a relatively large volume within the shaft 30 and, in some configurations, establishes a seal therein when fully saturated and expanded.

[0066] FIG. 23 shows another seal 2304 provided in accordance with the present disclosure for use at locations "A", "B", "E" (FIGS. 1, 2A-2C, and 6). For example, the seal 2304 may be configured to be positioned within an external structure, such as the shaft 30 (FIG. 1), to establish a seal around its inner surface. The seal 2304 includes a central opening 2306 and a plurality of radial openings 2308. The openings 2306, 2308 are configured to receive and sealingly engage operating components such as the articulation cable 38 (FIGS. 1, 4, and 5), the knife tube 62 (FIGS. 4 and 5), and the lead wire 99 (FIG. 1). Each of the openings 2306, 2308 includes a slit 2307, 2309, respectively, connecting the openings 2306, 2308 to the outer annular perimeter of the seal 2304 such that each of the operating components can slide laterally through one of the slits 2307, 2309 and enter into a sealing engagement within the corresponding openings 2306, 2308. The slits 2307, 2309 may be zero-closure slits.

[0067] As shown in FIG. 24, another seal configuration 2400 is provided that includes a seal member 2404 defining one or more apertures 2406 extending longitudinally therethrough. The seal configuration 2400 can be used at locations “A”, “B”, “E” (FIGS. 1, 2A - 2C, and 6) and / or any other suitable location. The seal member 2404 is configured to be inserted into a structure and to establish a seal against an inner surface of the structure, such as the inner surface of the shaft 30 (FIG. 1). The one or more apertures 2406 may be configured to receive actuating components, such as the articulation cable 38 (FIGS. 1, 4, and 5), the knife tube 62 (FIGS. 4 and 5), and the lead wire 99 (FIG. 1). A portion of the seal member 2404 is compressed radially inward, for example, via a band 2420 disposed around a portion of the seal member 2404, such that the one or more apertures 2406 are folded, and the seal member 2404 establishes a sealed engagement with the actuating component(s). The compressed portion of the seal member 2404 is no longer fully expanded to seal the shaft 30 (FIG. 1), but the shaft 30 can be sealed using another portion of the seal member 2404 or another seal (FIG. 1).

[0068] FIG. 25 provides a seal configuration 2500 that includes a seal member 2504 similar to the seal member 2404 (FIG. 24), except that rather than radial inward compression, the seal member 2504 is configured to be compressed axially inward from opposing ends to establish a seal within and / or around the shaft 30 and / or the actuating component(s) via compression of the seal member 2504 between two guide structures 39 disposed within the shaft 30. Alternatively, the seal member 2504 may be configured as any of the other seals detailed herein, such as the seal 2304 (FIG. 2), and held in a substantially fixed position within the shaft 30 between the guide structures 39 (with or without compression).

[0069] Turning to FIGS. 26A and 26B, as described above, one or more seals may be provided at or near the proximal end portion of the knife assembly 60, the knife drive assembly 300, and / or the jaw drive assembly 400 at location “C” (FIGS. 2A-2C). More specifically, a seal 2604 may be provided to seal the annular region between the knife drive parent screw 340 (and / or the knife tube 62) and the jaw drive rod 484.

[0070] The knife drive parent screw 340 may include a pair of diametrically opposed T-slots 2622 defined within its proximal sleeve portion 2620 without threads. The seal 2604 may define a pair of diametrically opposed T-projections 2624 that extend therefrom and are configured to complementarily engage within the T-slots 2622 to engage the seal 2604 with the knife drive parent screw 340. The seal 2604 functions as a cap to surround the open proximal end of the knife drive lead screw 340 and the knife tube 62 disposed therein, except for an opening 2626 defined through its proximal wall that sealingly receives the jaw drive rod 484. Thus, fluid moving proximally through the knife tube 62 is inhibited from passing proximally beyond the seal 2604.

[0071] Figures 27 and 28 show alternative seal arrangements for sealing between an inner component, such as the joe drive rod 484, and an outer component, such as the knife tube 62 or the knife drive lead screw 340, at or near location "C" of, for example, the knife assembly 60, the knife drive assembly 300, and / or the joe drive assembly 400 (see FIGS. 2A - 2C). The ends of the outer components 62, 340 are formed by internal annular pockets 2702, 2802 that surround lumens 2701, 2801 extending therethrough, for example, via machining. The pockets 2702, 2802 may be semi - circular as shown with respect to pocket 2702, V - shaped as shown with respect to pocket 2802, or define any other suitable configuration that allows for the capture of O - rings 2706, 2806 therein. The O - rings 2706, 2806 each project into the lumens 2701, 2801 and engage sealingly with an inner component, such as the joe drive rod 484 extending through the lumens 2701, 2801.

[0072] Referring to FIGS. 29A and 29B, the seal configuration 2900 is provided to establish a seal at or near location "D" at the distal end portion of the knife assembly 60 and / or the joe drive assembly 400, although other locations are contemplated (see FIGS. 1 - 6). More specifically, by sealing the open distal end of the knife tube 62 around the joe drive rod 484 extending therefrom in the seal configuration 2900, fluid is inhibited from entering and moving proximally through the knife tube 62.

[0073] Referring also to FIG. 1, instantaneously, the knife tube 62 extends proximally through the housing 20 and the proximal segment 34 of the shaft 30 to a position immediately adjacent to the articulation section 36 of the shaft 30 (see FIG. 1), and an intermediate elongate collar 66 engages around the distal end portion of the knife tube 62. The distal knife rod 64 engages the intermediate elongate collar 66 at an offset position, e.g., via a crimp tube 69, and extends distally through the articulation section 36 of the shaft 30 to the end effector assembly 40 (see FIG. 1), and the knife blade 68 engages the distal knife rod 64 distal to the articulation section 36 of the shaft 30. The distal knife rod 64 is flexible and / or includes one or more joints or articulation sections to enable articulation of the articulation section 36 of the shaft 30 through which the distal knife rod 64 extends. The jaw drive rod 484 extends distally through the knife tube 62 and through the articulation section 36 of the shaft 30 to the end effector assembly 40 (see FIG. 1), and the jaw drive rod 484 is operably coupled to the cam slot assembly 52, including enabling pivoting of the jaw member 42 between a spaced position (e.g., the open position of the end effector assembly 40) and an approximate position (e.g., the closed position of the end effector assembly 40) relative to the jaw member 44 and the distal segment 32 of the shaft 30 in response to translation of the jaw drive rod 484. Due to the offset engagement of the distal knife rod 64 and the intermediate collar 66, the jaw drive rod 484 can extend distally from the knife tube 62 to the end effector assembly 40. The jaw drive rod 484 is flexible and / or includes one or more joints or articulation sections to enable articulation of the articulation section 36 of the shaft 30 through which the jaw drive rod 484 extends.

[0074] Referring again to FIGS. 29A and 29B, the seal configuration 2900 includes a proximal seal member 2904 and a distal seal member 2906. The proximal seal 2904 is disposed around the knife tube 62 proximal to the intermediate elongate collar 66 and can also receive the proximal end portion of the distal knife rod 64 therein. The distal seal 2906 is disposed around the crimp tube 69 (including the distal knife rod 64 extending therethrough) or directly around the knife rod 64 (e.g., in a configuration where the crimp tube 69 is omitted or otherwise positioned). The distal seal 2906 is also disposed around the jaw drive rod 484 and is positioned distal to the intermediate elongate collar 66.

[0075] The proximal and distal seals 2904, 2906 are configured to slide towards each other and slide in a partially overlapping state around the intermediate elongate collar 66, with one of the seals, e.g., the proximal seal 2904, being partially received within the other seal, e.g., the distal seal 2906. Further, the proximal and distal seals 2904, 2906 include complementary engagement features, e.g., a lock tab 2908 extending from the inner seal, e.g., the proximal seal 2904, and a lock opening 2910 defined within the outer seal, e.g., the distal seal 2906. In this way, when the proximal and distal seals 2904, 2906 move into a partially overlapping state, the lock tab 2908 engages with the lock opening 2910, the second proximal and distal seals 2904, 2906 engage with each other, and together establish a seal around the intermediate elongate collar 66, the open distal end of the knife tube 62, and the jaw drive rod 484. The seal configuration 2900 can move with the knife tube 62 and / or allow translation of the jaw drive rod 484 relative thereto. Further, the proximal and distal seals 2904, 2906 can be formed from the same or different materials.

[0076] Figures 30A and 30B show another seal configuration 3000 provided to establish a seal at or near the distal end portion of the knife assembly 60 and / or the jaw drive assembly 400 at location "D", although other locations are contemplated (see FIGS. 1-6). The seal configuration 3000 is configured to seal an annular region defined between the open distal end of the intermediate elongate collar 66 (and / or the open distal end of the knife tube 62) and the jaw drive rod 484.

[0077] The seal configuration 3000 includes a plug 3004 that includes a body 3006 configured to establish a seal around the inner surface of the intermediate elongate collar 66 when inserted. The plug 3004 further includes a pair of opposed wings 3008, each defining a T-shaped configuration. The wings 3008 are configured to be received within opposed complementary T-shaped slots 3010 defined within the distal end portion of the intermediate elongate collar 66. The plug 3004 is inserted into the intermediate elongate collar 66 such that the body 3006 seals against the inner surface of the intermediate elongate collar 66, while the wings 3008 engage within the slots 3010 to secure and hold the plug 3004 in a sealed engagement within the intermediate elongate collar 66. The plug 3004 further includes a central lumen 3012 that extends therethrough and is configured to sealingly engage the jaw drive rod 484 (FIG. 30B) while allowing for its relative translation. The plug 3004 can be formed from an elastomeric material or other suitable material.

[0078] Turning to FIGS. 31A - 31C, another seal configuration 3100 is shown provided to establish a seal at or near the articulation motion section 36 (see also FIG. 1) of the shaft 30. The shaft 30 more specifically includes an articulation motion section 36 having one or more articulation components 37 (see FIG. 1). For example, one of the articulation components 37 (FIG. 1) may be a proximal link 3120 including a proximal body portion 3122, a distal surface 3124 disposed at the distal end of the proximal body portion 3122, and a pair of spaced pivot flags 3126 extending distally from the distal surface 3124. The pivot flags 3126 include bosses 3128 (see FIG. 1) that enable a pivotable connection between the proximal link 3120 and another articulation component 37 of the articulation motion section 36 of the shaft 30. The proximal body portion 3122 may be configured to insert into the proximal segment 34 of the shaft 30, and the distal surface 3124 is adjacent to the open distal end of the proximal segment 34 of the shaft 30 (see FIG. 1).

[0079] Continuing to refer to FIGS. 31A - 31C, the seal configuration 3100 includes a plug 3130, a seal ring 3140, and a clip 3150. The seal ring 3140 can be formed of an elastomer or other suitable material. The plug 3130 and the clip 3150 may be formed of an elastomeric material or a more rigid material. The plug 3130 includes a base 3132 configured to be proximally adjacent to the proximal body portion 3122 of the proximal link 3120, and a pair of opposing arms 3134 extending distally from the base 3132. The arms 3134 are configured to engage within corresponding slots 3136 defined within the proximal body portion 3122 of the proximal link 3120. The seal ring 3140 is configured to be proximally adjacent to the base 3132 of the plug 3130, and the clip 3150 includes a base 3152 configured to be proximally adjacent to the seal ring 3140, and arms 3154 extending through the seal ring 3150 and configured to engage, for example, in a snap - fit manner, with slots 3138 in the base 3132 of the plug 3130, thereby fixing the seal 3130 and the clip 3150 to each other with the seal ring 3140 disposed therebetween.

[0080] In the assembled state, the plug 3130, the seal ring 3140, and the clip 3150 cooperate with each other, and the proximal body portion 3122 of the proximal link 3120 establishes a seal within the inner surface of the proximal segment 34 of the shaft 30 (see FIG. 1) via, for example, the outer annular surface of the seal ring 3140, and seals and guides the operating components extending through the proximal segment 34 of the shaft 30 (see FIG. 1). More specifically, the seal ring 3140 includes a central opening 3142 configured to sealingly receive the joystick drive rod 484 (FIG. 2C), a plurality of, for example, four radially arranged openings 3144 (FIG. 1) configured to sealingly receive the articulation cable 38, a pair of adjacent openings 3146 (FIG. 1) configured to sealingly receive the lead wire 99, and an offset opening 3148 (see FIG. 29A) configured to sealingly receive the distal knife rod 64 or the crimp tube 69 disposed therearound. The clip 3150 defines an opening 3156 and / or a notch 3158 to provide access to the various openings 3142 - 3148 defined through the seal ring 3140. The plug 3130 may similarly include a passage 3139, such as an opening and / or a channel, for the operating components to pass through.

[0081] FIG. 32 shows yet another seal configuration 3200 that is similar to the seal configuration 3100 (Figs. 31A - 31C) and is configured to operably engage the proximal body portion 3122 of the proximal link 3120 to establish a seal at or near the articulation zone 36 of the shaft 30 at location “E” (see also Fig. 1). The seal configuration 3200 includes an engagement plug 3230, an outer seal ring 3240, and an inner seal plug 3260. The seal ring 3240 and the seal plug 3260 can be formed from an elastomer or other suitable material, and the engagement plug 3230 can be formed from an elastomer material or a more rigid material. The engagement plug 3230 includes a base 3232, a pair of opposing arms 3234 extending distally from the base 3232, and a central cylinder 3237 extending distally from the base 3232 between the arms 3234. The outer seal ring 3240 is configured to be positioned around the central cylinder 3237 and between the arms 3234, and the inner seal plug 3260 is configured to be distally adjacent to the distal end portion of the central cylinder 3237. The engagement plug 3230 engages the proximal body portion 3122 of the proximal link 3120 in a sealing engagement with the seal ring 3240 disposed therebetween and engages the seal plug 3260 extending into the central cylinder 3237 and the proximal body portion 3122 of the proximal link 3120 in a sealing engagement to form a seal between the inner surface of the proximal link 3120, for example, in a manner similar to that detailed above with respect to the seal configuration 3100 (Figs. 31A - 31C) via the engagement of the arms 3234 in the slots. In use, the outer seal ring 3240 establishes a seal within the inner surface of the proximal segment 34 of the shaft 30 (see Fig. 1), seals around the articulation cable 38 (Fig. 1), and the inner seal plug 3260 seals around the jo - drive rod 484 (Fig. 2C), the lead wire 99 (Fig. 1), and the distal knife rod 64 (see Fig. 29A).

[0082] Referring to FIG. 33, there is provided yet another seal configuration 3300 similar to seal configurations 3100, 3200 (FIGS. 31A-31C and FIG. 32 respectively), which is configured to operably engage with the proximal body portion 3122 of the proximal link 3120 to establish a seal at or near the articulation section 36 (see also FIG. 1) of the shaft 30 at location “E”.

[0083] Seal configuration 3300 includes a plug 3330, an outer seal ring 3350, and an O-ring seal 3370. The plug 3330 includes a base 3332 and a conical body 3338 extending distally from the base 3332. The conical body 3338 is configured to be inserted into the proximal body portion 3122 of the proximal link 3120. The plug 3330 may be configured to engage the proximal body portion 3122 in any suitable manner, such as by press-fitting, via arm and slot engagement, etc. The outer seal ring 3350 is configured to engage within a slot 3333 defined within the plug 3330 between the base 3332 and its conical body 3338. The outer seal ring 3350 projects radially outwardly from the plug 3330 and the proximal body portion 3122 of the proximal link 3120 to enable formation of a seal within the inner surface of the proximal segment 34 of the shaft 30 (see FIG. 1). The outer seal ring 3350 further defines a radial lumen for sealingly engaging the articulation cable 38 with the distal knife rod 64 or the crimp tube 69 (see FIG. 29A). The O-ring seal 3370 is disposed within the central lumen 3331 of the plug and is configured to seal the joe drive rod 484.

[0084] FIGS. 34-40 show various mechanisms for manually actuating the end effector assembly 40 (e.g., the joe members 42, 44) for inspection, cleaning, and sterilization, or for loading various hardware onto the end effector assembly 40 for use during operation. It is contemplated that one or more of the mechanisms and features described below may be applied to other aspects of the surgical instrument 10 depending on a particular purpose and to enable its manual actuation.

[0085] Each of the following figures briefly describes the operation of the end effector assembly 40 in relation to its respective manual operation functions. A more detailed description of the robotic-assisted operation of the end effector assembly 40 is described above, and thus only the details necessary for a complete understanding of the manual operation components are described herein.

[0086] Figure 34 is an internal cross-sectional view of the various jaw operating components described in detail above, showing one general procedure for manually operating the end effector assembly 40 using one or more of the above designs. More specifically, the jaw operating assembly 4020 includes a compression assembly 4055 configured to house a spring force assembly 4050, and a jaw drive assembly 4005 including a jaw input gear 4022 operably coupled to a jaw drive input 4035. The spring force assembly 4050 includes a distal hub 4054, a proximal hub 4052, a drive gear 4030, and a lock tab 4075. Each hub 4052, 4054 includes an inner circumferential surface having a plurality of teeth 4053, 4057 configured to matingly engage corresponding pluralities of teeth or threads 4031 of the drive gear 4030.

[0087] Manual operation of the jaw drive input 4035 rotates the jaw input gear 4022 that is coupled to the drive gear 4030. Rotation of the drive gear 4030 linearly translates the proximal hub 4052 of the spring force assembly 4050 against the biasing of the compression spring 4056 relative to the distal hub 4054, and then linearly translates the jaw drive rod 4084 by mechanical engagement between the proximal end of the jaw drive rod 4084 and the lock tab 4075. The jaw members 42, 44 can be manually opened and closed as needed in this manner.

[0088] Figures 35A-35B are, respectively, a side view and an internal perspective view of one embodiment of a manual joystick actuation assembly 4120. In this embodiment, a thumb wheel 4125 is provided that extends through the joystick housing 20 for external access by an operator. The thumb wheel 4125 is operably engaged with a plurality of threads 4111 on a joystick input shaft 4110 that is distal to a spring compression assembly 4155. Rotation of the thumb wheel 4125 rotates the joystick input shaft 4110, which in turn translates a proximal hub (not shown, see FIG. 34 above) of the spring compression assembly 4155.

[0089] Figures 36A-36B are inner side views of yet another embodiment of a manual joystick actuation assembly 4220. In this embodiment, a thumb wheel 4225 is included, as in the previous embodiment, and extends outside of the joystick housing 20 for external manual actuation. The thumb wheel 4225 is operably engagable with a spring compression assembly 4255 and is mounted thereto via a support shaft 4226 configured to be positioned within a slot 4256 defined therein. More specifically, the shaft 4226 is supported within the slot 4256 on a leaf spring 4227 configured to bias the thumb wheel 4225 to a disengaged position. The thumb wheel 4225 is selectively movable relative to the spring compression assembly 4255 (e.g., in direction "P") between a disengaged position (FIG. 36A) spaced from a drive gear 4230 of the spring compression assembly 4255 and an engaged position where the thumb wheel 4225 is operably engaged with the drive gear 4230, and manually rotating the drive gear 4230 translates a proximal hub 4252 of the spring compression assembly 4255 against the bias of the leaf spring 4227 (FIG. 36B) relative to a distal hub 4254 of the spring compression assembly 4255. As described above, the spring 4236 is compressed by translation of a joystick drive rod 4284 via translation of the proximal hub 4252 relative to the distal hub 4254.

[0090] When the thumb wheel 4225 is disposed at the engagement position, the manual rotation of the thumb wheel 4225 correspondingly translates the joe drive rod 4284 to open and close the joe members 42 and 44. When the thumb wheel 4225 is released, the thumb wheel 4225 releases the drive gear 4230 under the biasing force of the leaf spring 4227 and returns to the disengaged position (FIG. 36B).

[0091] FIGS. 37A-37E are various views of yet another embodiment of the manual joe actuation assembly 4320. In this embodiment, similar to the previous embodiment, a thumb wheel 4325 is included and extends outside the joe housing 20 for external manual actuation. The thumb wheel 4325 is operably engagable with the joe input shaft 4310 of the joe drive input portion 4335. More specifically, the thumb wheel 4325 is positioned on top of the joe input shaft 4310 distal to the compression assembly 4355 and is laterally movable for the user to perform manual actuation thereon. A spring (not shown) can be included to bias the thumb wheel 4325 to the disengaged position.

[0092] The joe input shaft 4310 includes a series of castellations 4380 defined therein and configured to matingly engage a corresponding series of teeth 4326 disposed on the inner circumferential surface of the thumb wheel 4325. The user presses the thumb wheel 4325 in the distal direction to engage the castellations 4380 and the corresponding teeth 4326, and then rotates the thumb wheel 4325 to rotate the joe input shaft 4310 to open and close the joe members 42 and 44. Other mechanical contact surfaces are envisioned to achieve this purpose. The user can manually engage and disengage the joe input shaft 4310 as needed to actuate the joe members 42 and 44. When the thumb wheel 4325 is engaged under spring biasing, when the user releases the thumb wheel 4325, the thumb wheel 4325 is automatically disengaged from the joe input shaft 4310, enabling smooth robot operation during surgery.

[0093] Figures 38A - 38B are schematic views of yet another embodiment of the manual joystick actuation assembly 4420. In this embodiment, similar to the previous embodiment, a thumb wheel 4425 is included and extends outside the joystick housing 20 for external manual actuation. Similar to the embodiment shown in Figures 37A - 37E, the thumb wheel 4425 is manually engageable and disengageable with the joystick input shaft 4410. In this embodiment, the thumb wheel 4425 is movable radially (see arrow "R") to engage and disengage the joystick input shaft 4410.

[0094] More specifically, the thumb wheel 4425 includes a series of teeth 4426 disposed on the inner circumferential surface of the thumb wheel 4425, and the joystick input shaft 4410 includes a gear 4412 having a series of corresponding teeth 4416 disposed on its outer circumference. The user presses the thumb wheel 4425 towards the joystick input shaft 4410 to engage a series of teeth 4416 of the gear 4412 with the corresponding teeth 4426 of the thumb wheel 4425, and then rotates the thumb wheel 4425 to rotate the joystick input shaft 4410 to open and close the joystick members 42, 44. The user can manually engage and disengage the joystick input shaft 4410 as needed to actuate the joystick members 42, 44. When the thumb wheel 4425 engages under spring bias (the spring is not shown), when the user releases the thumb wheel 4425, the thumb wheel 4425 is automatically disengaged from the joystick input shaft 4410, enabling smooth robot operation during surgery.

[0095] Figures 39A - 39F show embodiments of a selectively removable lock tab 4575 for use with a spring assembly 4550. More specifically, the spring assembly 4550 includes a compressor cap 4555 configured to receive a compression spring 4556 mounted on a compressor stem 4545. The compressor stem 4545 includes an inner circumference 4547 defined therein and configured to receive a joe drive rod 4584 therethrough. The proximal end 4549 of the compressor stem 4545 includes an opening 4551 defined therein and configured to be horizontally aligned with the joe drive rod 4584 for reception thereof therein. Further, the proximal end 4549 includes a vertical slot 4546 defined therein that extends through the opening 4551 and is configured to selectively receive the lock tab 4575 therein.

[0096] The lock tab 4575 includes a gripping tab 4577 that extends from its upper end and is configured to be selectively gripped by a user to lock and unlock the joe drive rod 4584 as needed during assembly and disassembly. The lock tab 4575 includes a stem 4576 that extends from the gripping tab 4577 having a keyhole 4560 defined therein that includes an upper opening 4579 and a lower, larger opening 4578. The lock tab 4575 is configured to be received in the slot 4546 of the compressor stem 4545.

[0097] The proximal end 4585 of the joe drive rod 4584 is key-shaped such that it includes a first section 4588 at its proximal most end configured to be received through the opening 4551 of the compressor stem 4545 and a second section 4586 sized larger than the opening 4551. A recess 4587 is defined between the first section 4588 and the second section 4586.

[0098] As shown in FIGS. 39B - 39D, during assembly, the compressor stem 4545, the compressor spring 4550, and the compressor cap 4555 are assembled, and the lock tab 4575 is inserted into the slot 4546 of the compressor stem 4545 to reach the first load position, and the lower opening 4578 of the lock tab 4575 aligns with the opening 4551 of the compressor stem 4545. Next, the proximal end 4585 of the joe drive rod 4584 is loaded into the inner circumference 4547 of the compressor stem 4545 such that the first section 4588 of the proximal end 4585 extends through the opening 4578 of the lock tab 4575 and the opening 4551 of the compressor stem. The second section is pushed in to contact the larger opening 4578. When seated, the lock tab 4575 is further pushed into the compressor stem 4545, and the opening 4579 engages and slides over the recess 4587 to lock the joe drive rod 4584 in place for use (see FIG. 39F).

[0099] To remove the joe drive rod 4584, the user simply grips the grip tab 4577 and pulls the lock tab 4575 away from the housing 20. This disengages the opening 4579 from the recess 4587, aligns the first section 4588 with the opening 4551, and allows the joe drive rod 4584 to be removed from the inner circumference 4547 of the compressor stem 4545 (see FIG. 39E).

[0100] FIG. 40 is a side view of yet another embodiment of the manual joe - actuated assembly 4620. In this embodiment, similar to the previous embodiment, a thumb slide 4625 is included and is operable from the outside of the joe housing 20. The thumb slide 4625 is operably coupled to a spring compressor assembly 4655 such that when the thumb slide 4625 is slid in either direction, the spring compressor assembly 4655 moves. More specifically, sliding the spring compressor assembly 4655 moves the distal hub relative to the proximal hub (e.g., the distal and proximal hubs 4054, 4052 of FIG. 34), and then the joe drive rod (e.g., the joe drive rod 4084 of FIG. 34) moves to open and close the joe members 42, 44. A spring (not shown) can be used to bias the slide in a particular direction.

[0101] It will be understood that various modifications can be made to the aspects disclosed in this specification. Accordingly, the above description should not be construed as limiting, but rather should be construed merely as illustrative of various aspects and features. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.

Claims

**Claim 1**: A robotic surgical instrument, wherein the robotic surgical instrument comprises: a housing; a shaft extending distally from the housing; an end effector assembly disposed at a distal end portion of the shaft; at least one drive gear disposed within the housing; a drive rod extending distally from the housing through the shaft to the end effector assembly, the drive rod being coupled between the at least one drive gear and the end effector assembly, wherein operation of the at least one drive gear actuates the end effector assembly by moving the drive rod relative to the shaft, and the at least one drive gear is adapted to be connected to a surgical robot for moving the drive rod by driving rotation of the at least one drive gear; a lock tab within the housing for selectively coupling the at least one drive gear to the drive rod; and comprising; the lock tab is movable between an engaged position and a disengaged position; in the engaged position, the lock tab maintains the coupling of the at least one drive gear to the drive rod; in the disengaged position, the lock tab disengages the at least one drive gear from the drive rod, thereby enabling the end effector assembly to be actuated independently of the at least one drive gear. A robotic surgical instrument. **Claim 2**: The robotic surgical instrument according to claim 1, further comprising a spring assembly for coupling the drive rod to the at least one drive gear. **Claim 3**: The robotic surgical instrument according to claim 2, wherein the spring assembly includes a first hub coupled to the at least one drive gear, a second hub coupled to the drive rod, and a spring disposed between the first hub and the second hub. **Claim 4**: The robotic surgical instrument according to claim 3, wherein in the engaged position of the lock tab, the drive rod is coupled to the second hub of the spring assembly, and in the disengaged position of the lock tab, the drive rod is disengaged from the second hub of the spring assembly. **Claim 5**: The robot surgical instrument according to any one of claims 3 to 4, wherein the spring is configured to adjust a force applied from the first hub to the second hub. **Claim 6**: The robot surgical instrument according to any one of claims 1 to 5, wherein the lock tab is received within a slot associated with the at least one drive gear, and the lock tab includes a keyhole configured to receive a key of the drive rod. **Claim 7**: The robot surgical instrument according to claim 6, wherein the lock tab is slidable within the slot between the engaged position and the disengaged position, and at the engaged position, the key is engaged with the keyhole, and at the disengaged position, the key is disengaged from the keyhole. **Claim 8**: The robot surgical instrument according to any one of claims 1 to 7, wherein the lock tab is movable from the engaged position to the disengaged position away from the housing. **Claim 9**: The robot surgical instrument according to any one of claims 1 to 8, wherein the end effector assembly includes a first jaw member and a second jaw member, and actuating the end effector assembly includes moving the first jaw member or the second jaw member relative to at least one of the first jaw member or the second jaw member. **Claim 10**: The robot surgical instrument according to claim 1, wherein at least one of the first jaw member or the second jaw member is adapted to be connected to an energy source to conduct energy through tissue grasped between the first jaw member and the second jaw member. **Claim 11**: The robot surgical instrument according to any one of claims 1 to 10, wherein the at least one drive gear includes a lead screw and a collar threadedly engaged around the lead screw. **Claim 12**: The robot surgical instrument according to any one of claims 1 to 11, wherein the shaft includes an articulating portion configured to articulate the end effector assembly relative to the housing.

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