Surgical instruments and related methods

Abstract

The present invention relates to surgical instruments, and more specifically, to actuators for surgical instruments. [Solution] A surgical instrument and related methods are disclosed. The instrument comprises a first jaw, a second jaw, and a first actuator. The first actuator has a cam mechanism that engages with the first jaw and moves the first jaw between an open position, a clamped position, and a closed position. The movement of the first jaw between the open position and the clamped position includes a rotational component. The movement of the first jaw between the clamped position and the closed position is a translational component.

Description

Technical Field

[0001] (Cross - reference to Related Applications) This application is a US Provisional Patent Application No. 62 / 670,193, filed on May 11, 2018, and claims priority to "Surgical Instruments and Related Methods", the entire disclosure of which is incorporated herein by reference for all appropriate purposes.

[0002] The present invention generally relates to surgical instruments, and more particularly, to actuators for surgical instruments.

Background Art

[0003] There is a need for improved actuators for surgical instruments, particularly for small instruments such as, for example, surgical stapling instruments having a diameter of 5 millimeters or less, as well as for other new and useful improvements.

Summary of the Invention

Means for Solving the Problems

[0004] An exemplary surgical instrument has a first jaw, a second jaw, and a first actuator. The first actuator has a cam mechanism that engages with the first jaw to enable movement of the first jaw between an open position, a clamp position, and a closed position. The movement of the first jaw between the open position and the clamp position includes a rotational movement component. The movement of the first jaw between the clamp position and the closed position is a translational movement.

[0005] An exemplary method of using a surgical instrument includes moving a first actuator between a first position and a second position abutting the first position to move the first jaw between an open position and a clamped position. An exemplary method also includes moving the first actuator between a second position and a third position abutting the second position to move the first jaw between a clamped position and a closed position. The movement of the first jaw between the open position and the clamped position includes a rotational component. The movement of the first jaw between the clamped position and the closed position is a translational component. [Brief explanation of the drawing]

[0006] [Figure 1] Figure 1 is a side view of an exemplary end effector having a first jaw in the open position. [Figure 2] Figure 2 is a side view of the end effector in Figure 1 at the clamping position. [Figure 3] Figure 3 is a side view of the end effector in Figure 1 in the closed position. [Figure 4] Figure 4 is a side view of the first jaw of the end effector in Figure 1. [Figure 5] Figure 5 is a detailed side view of the first jaw and first actuator of the end effector shown in Figure 1. [Figure 6] Figure 6 is a side view of a portion of the second jaw of the end effector in Figure 1. [Figure 7] Figure 7 is a perspective view of the end effector shown in Figure 1. [Figure 8] Figure 8 is a flowchart illustrating an exemplary method. [Modes for carrying out the invention]

[0007] Referring to Figures 1-3, an exemplary end effector 100 for a surgical instrument is shown. The end effector 100 may be referred to herein as surgical instrument 100. The surgical instrument may be a surgical stapler, but those skilled in the art will recognize that the teaching herein is also suitable for other instruments, in particular for internal surgical sealers or other surgical instruments that require precise gripping and clamping of tissue in a confined space.

[0008] As illustrated, the surgical instrument 100 comprises an upper or first jaw or anvil 102 and a lower or second jaw 104, which may also be referred to herein as a cartridge holder or cartridge 104. The instrument 100 may have an actuator 106 configured to engage with the maxilla 102 and move the maxilla between an open position (e.g., see Figure 1), a clamped position (e.g., see Figure 2), and / or a closed position (e.g., see Figure 3). For the purposes of this manuscript, the term “clamped position” should be understood as a position in which the maxilla and mandible are positioned close to each other and act on tissue positioned between the two jaws. The term “closed position” should be understood as a position in which the maxilla and mandible are positioned closer together than in the clamped position and, in some embodiments, may be in contact with each other at one or more positions along the tissue interaction region of the jaws. The term “open position” should be understood as a position in which at least the tips of the jaws are further apart than they are in the clamped position, or the jaws are rotated away from each other.

[0009] The actuator 106 may be configured to move longitudinally or in a parallel direction, and longitudinal movement of the actuator acts to rotate the maxilla between the open position and the clamped position and to linearly translate the maxilla between the clamped position and the closed position. Figure 1 shows the actuator 106 in a proximal position relative to the second jaw 104 and / or the first jaw 102. Figure 2 shows the actuator 106 in a second position which is distal to the proximal position shown in Figure 1. Figure 3 shows the actuator 106 in a third position which is distal to both positions shown in Figures 1 and 2.

[0010] In some examples, the device 100 includes a multi-position cam system having (a) an anvil 102, (b) an actuator 106, (c) a housing 104 having a pivot member or pivot pin 108 and an actuator guide slot 126, and (d) a spring member.

[0011] In some examples, a surgical instrument comprises a maxilla, which may be an anvil for a surgical stapler; a mandible, which may be a cartridge housing; and a first actuator. The first actuator may have a cam configured to move the maxilla between an open position, a clamped position, and a closed position. The movement of the maxilla between the open and clamped positions may include a rotational and a translational component. In some embodiments, the movement of the maxilla between the open and clamped positions is strictly rotational. The movement of the maxilla between the clamped and closed positions may be substantially translational, with little to no rotational component. In some embodiments, the movement of the maxilla between the clamped and closed positions is strictly translational.

[0012] The first actuator may have a cam mechanism having multiple cam surfaces to engage with multiple surfaces of the maxilla to perform a desired movement of the maxilla. The cam mechanism may have a first cam surface, a second cam surface, and a third cam surface. The maxilla has a first jaw surface, a second jaw surface, and a third jaw surface, the second jaw surface located on the tip side of the first and third jaw surfaces, and the first jaw surface located on the root side of the second and third jaw surfaces.

[0013] As shown in Figures 1 and 2, the first cam surface may be configured to engage with the first jaw surface as the first actuator moves toward the tip from a first position to a second position, thereby rotating the maxilla from an open position to a clamped position.

[0014] As shown in Figure 3, the second cam surface may be configured to engage with the second jaw surface when the first actuator is moved tipwise from the second position to the third position, thereby translating the maxilla from the clamped position to the closed position.

[0015] Furthermore, as can be seen in Figure 3, the third cam surface can be configured to engage with the third jaw surface when the first actuator moves from the third position to the fourth position towards the root, thereby causing a parallel movement of the maxilla from the closed position to the clamped position.

[0016] As shown in Figures 1-3, the pin may be positioned on either the maxilla or the mandible, and the elongated slot may be positioned on the other of the maxilla or mandible. The pin and the elongated slot are configured to allow the pivot axis of the maxilla to move parallel between a first position and a second position.

[0017] The apparatus may include a second actuator substantially identical to the first actuator and positioned on the opposite side of the longitudinal axis of the apparatus. A translation member may be positioned between the first actuator and the second actuator. The translation member may include a cutting mechanism and / or a clamping member such as an expanding I-beam as described in the jointly owned U.S. Patent Application Publication No. 2016 / 0345971(A1), published on December 1, 2016, under the title "Surgical Stapler." The entire disclosure of this patent document is incorporated herein by reference for appropriate purposes.

[0018] Although not shown, the instrument may include a biasing mechanism for biasing the instrument toward an open or closed position. Those skilled in the art will recognize that there are many means for providing a biasing mechanism or feature, including, but not limited to, springs, magnets, low-durometer polymers, etc. In some embodiments, the biasing mechanism is configured to apply a parallel force to the maxilla so as to bias the maxilla or anvil from a closed position to a clamped position or vice versa. In some embodiments, the biasing mechanism is configured to apply a rotational force to the maxilla so as to bias the maxilla or anvil from a clamped position to an open position or vice versa. In some embodiments, the biasing mechanism is configured to apply forces that tend to translate and rotate the maxilla or anvil.

[0019] In some embodiments, the biasing mechanism is configured to bias the lower surface of the elongated slot to the pivot pin (see, for example, Figure 2). In some embodiments, the maxilla moves between a clamped position and an open position while the lower surface is maintained in contact with the pivot pin. In some embodiments, the actuator is configured to bring the upper surface of the elongated slot into contact with the pivot pin (see, for example, Figure 3).

[0020] In some embodiments, the instruments described herein reduce the degrees of freedom in the system and provide an optimized geometry for maximum element strength. That is, when moving between the open position and the clamp position, the jaws are restricted to relative rotational movement. In some embodiments, a biasing mechanism and an actuator as described herein may perform this movement. When moving between the closed position and the clamp position, the jaws are restricted to relative translational movement. In some embodiments, a biasing mechanism and an actuator as described herein may perform this movement.

[0021] Referring now to FIG. 4, in some embodiments, the second and third cam surfaces of the upper jaw may be parallel to each other.

[0022] As shown in FIG. 5, in some embodiments, the second and third cam surfaces of the upper jaw can contact the actuator simultaneously when moving between the clamp position and the closed position. By having two contact point supports, the movement of the upper jaw or anvil relative to translational movement between the clamp position and the closed position can be restricted and / or the structural integrity of the instrument can be improved. In some embodiments, the biasing mechanism tends to rotate the jaws open, while contact at the two cam surfaces on the upper jaw or anvil performs translational movement and counteracts the tendency of the upper jaw or anvil to rotate.

[0023] As shown in FIG. 6, the housing may include one or more flange surfaces for engaging a protrusion on the actuator to support the tip of the actuator, thereby improving the structural integrity of the instrument while allowing for a small structure.

[0024] As shown in the figures, in FIGS. 1-3, in some embodiments, the upper jaw or anvil is restricted to translational movement unless a preselected pivot axis of the upper jaw or anvil is aligned with a defined lateral axis of the lower jaw, cartridge, or housing.

[0025] Following Figures 1-3, in some embodiments, one or more of the first, second, and third cam surfaces on the maxilla or anvil are positioned on or below the root side of a pre-selected pivot axis. In some embodiments, each of the first, second, and third cam surfaces of the maxilla or anvil is positioned on or below the root side of a pre-selected pivot axis.

[0026] Next, with reference to Figure 8, an exemplary method 800 is described. Method 800, using a surgical instrument having a first jaw, a second jaw, and a first actuator having a cam mechanism for engaging with the first jaw, includes moving the first actuator between a first position and a second position further forward than the first position 802, so that the movement of the first jaw can be between an open position and a clamped position. Method 800 includes moving the first actuator between a second position and a third position further forward than the second position 804, so that the movement of the first jaw can be between a clamped position and a closed position. The movement of the first jaw between the open position and the clamped position is rotational in some embodiments. In some embodiments, the movement of the first jaw between the clamped position and the closed position is translational.

[0027] Moving the first actuator can consist of translating the first actuator.

[0028] In some embodiments, the cam mechanism has a first cam surface, a second cam surface, and a third cam surface. In some embodiments, the first jaw has a first jaw surface, a second jaw surface, and a third jaw surface, the second jaw surface being located on the tip side of the first and second jaw surfaces, and the first jaw surface being located on the root side of the second and third jaw surfaces. In some embodiments, to enable rotation of the first jaw from the open position to the clamped position, the movement of the first actuator engages the first cam surface with the first jaw surface when the first actuator is moved tip-side from the first position to the second position. To translate the first jaw from the clamped position to the closed position, the movement of the first actuator engages the second and third cam surfaces with the second jaw surface when the first actuator is moved tip-side from the second position to the third position. When the first actuator is moved from the third position toward the root in order to move the first jaw from the closed position to the clamped position, the movement of the first actuator engages the third cam surface with the third jaw surface.

[0029] Some embodiments of method 800 may include biasing the first jaw toward an open position.

[0030] Some embodiments of Method 800 may include moving the pivot axis of the first jaw between a first position and a second position different from the first position.

[0031] Some embodiments of this method may include using a second actuator to move a translation member located between the first actuator and the second actuator.

[0032] Each of the various elements disclosed herein can be achieved in various ways. This disclosure should be understood to include any modified embodiment of any apparatus, method or process embodiment, or simply a modified form of any of these components. In particular, it should be understood that the terms for each element can be expressed in equivalent apparatus or method terminology, even if only the function or result is the same. Such equivalent, broader, or even more comprehensive general terms should be considered to be encompassed in the description of each component or operation. To express the potentially broader scope for which the invention is entitled, such terms may be substituted where desired.

[0033] However, as one example, it should be understood that all actions can be expressed as means to take that action or as elements that cause that action. Similarly, each physical element disclosed should be understood to encompass the disclosure of the action that the physical element facilitates. With respect to this last aspect, as merely an example, the disclosure of an actuator should be understood to encompass the disclosure of the act of acting—whether or not it is explicitly discussed—and conversely, whether or not only the disclosure of the act of acting existed, such disclosure should be understood to encompass the disclosure of the “actuating mechanism.” Such modifications and alternative terms should be understood to be expressly included herein.

[0034] The foregoing description of the disclosed embodiments is provided to enable those skilled in the art to manufacture or use the invention. Various modifications to these embodiments will be readily apparent to those skilled in the art, and the general principles defined herein may be applied to other embodiments without departing from the spirit or scope of the invention. Accordingly, the invention is not limited to the embodiments shown herein, but is intended to follow the broadest scope consistent with the principles and novel features disclosed herein. The following are some examples of examples of how this can be implemented. [Reference Mode 3] The first jaw and, The second jaw and A first actuator having a cam mechanism configured to engage with the first jaw to move the first jaw between an open position, a clamped position, and a closed position, A surgical instrument in which the movement of the first jaw between the open position and the clamped position includes a rotational component, and the movement of the first jaw between the clamped position and the closed position is a translational component. [Reference Mode 2] The cam mechanism has a first cam surface, a second cam surface, and a third cam surface. The first jaw has a first jaw surface, a second jaw surface, and a third jaw surface, the second jaw surface being positioned towards the tip of the first and second jaw surfaces, and the first jaw surface being positioned towards the base of the second and third jaw surfaces. In order to rotate the first jaw from the open position to the clamped position, the first actuator is configured to engage with the first jaw surface when it moves from the first position to the second position toward the tip, When the first actuator moves from the second position to the third position toward the tip in order to move the first jaw in parallel from the clamp position to the closed position, the second cam surface and the third cam surface are configured to engage with the second jaw surface. The surgical instrument according to Reference Embodiment 1, wherein when the first actuator moves from the third position to the fourth position toward the root in order to move the first jaw in parallel from the closed position to the clamped position, the third cam surface is configured to engage with the third jaw surface. [Reference Embodiment 3] The surgical instrument according to reference embodiment 1, further comprising a biasing mechanism configured to bias the first jaw toward the open position. [Reference Embodiment 4] The biasing mechanism is configured to apply a parallel force to the first jaw, as described in reference embodiment 3 of the surgical instrument. [Reference Method 5] The biasing mechanism is configured to apply a rotational force to the first jaw, as described in reference embodiment 3 of the surgical instrument. [Reference Embodiment 6] A pin positioned on either the first jaw or the second jaw, The present invention further comprises an elongated slot located on the other of the first jaw or the second jaw, The surgical instrument according to reference embodiment 1, wherein the pin and the elongated slot are configured to allow the pivot axis of the first jaw to move in parallel between a first position and a second position different from the first position. [Reference aspect 7] The second actuator and A surgical instrument according to reference embodiment 1, further comprising a translation member disposed between the first actuator and the second actuator. [Reference Mode 8] The aforementioned translation member is equipped with a cutting mechanism, as described in reference embodiment 7, a surgical instrument. [Reference aspect 9] The surgical instrument according to reference embodiment 1, wherein the movement of the first jaw between the open position and the clamped position has a parallel movement component. [Reference Embodiment 10] A method of using a surgical instrument comprising a first jaw, a second jaw, and a first actuator having a cam mechanism configured to engage with the first jaw, The steps include moving the first actuator between a first position and a second position on the tip side of the first position in order to move the first jaw between an open position and a clamped position, The method includes the step of moving the first actuator between the second position and a third position on the tip side of the second position in order to move the first jaw between the clamp position and the closed position, The movement of the first jaw between the open position and the clamped position has a rotational component. The movement of the first jaw between the clamp position and the closed position is a translational movement, in this method. [Reference Embodiment 11] The method according to reference embodiment 10, wherein the movement of the first actuator is to move the first actuator in parallel. [Reference Embodiment 12] The cam mechanism has a first cam surface, a second cam surface, and a third cam surface. The first jaw comprises a first jaw surface, a second jaw surface, and a third jaw surface, wherein the second jaw surface is located on the tip side of the first and second jaw surfaces, and the first jaw surface is located on the base side of the second and third jaw surfaces. The movement of the first actuator causes the first cam surface to engage with the first jaw surface when the first actuator is moved toward the tip from the first position to the second position, in order to bring about the rotation of the first jaw from the open position to the clamped position. The movement of the first actuator involves moving the first actuator toward the tip from the second position to the third position in order to move the first jaw in parallel from the clamp position to the closed position, thereby engaging the second cam surface and the third cam surface with the second jaw surface. The movement of the first actuator is the method according to reference embodiment 10, wherein the movement of the first actuator is such that the third cam surface engages with the third jaw surface when the first actuator is moved from the third position toward the root in order to move the first jaw in parallel from the closed position to the clamping position. [Reference Embodiment 13] The method according to reference embodiment 10, further comprising the step of biasing the first jaw toward the open position. [Reference Embodiment 14] The method according to reference embodiment 10, further comprising the step of moving the pivot axis of the first jaw between a first position and a second position different from the first position. [Reference Embodiment 15] The method according to reference embodiment 10, further comprising the step of using the second actuator to move a translation member positioned between the first actuator and the second actuator. [Reference Embodiment 6] The method according to reference embodiment 10, wherein the movement of the first jaw between the open position and the clamped position includes a translation component.

Claims

1. A first jaw having a tip and a posterior end, The second jaw and A first actuator having a cam mechanism configured to engage with the first jaw to move the first jaw between an open position, a clamped position, and a closed position, The movement of the first jaw between the open position and the clamped position includes a rotational movement component. The movement of the first jaw between the clamp position and the closed position is a parallel movement. The first jaw is configured to pivot relative to the second jaw about a pivot axis, The first actuator has a first cam surface that engages with the first jaw surface of the first jaw, The engagement between the first cam surface and the first jaw surface by the forward movement of the first actuator from a first position to a second position causes the first jaw to pivot relative to the second jaw from the open position to the clamped position, in a surgical instrument.

2. The first actuator has a second cam surface that engages with the second jaw surface of the first jaw, and the first actuator has a third cam surface that engages with the third jaw surface of the first jaw. The engagement between the second cam surface and the second jaw surface by the forward movement of the first actuator from the second position to the third position causes the first jaw to move parallel to the second jaw from the clamp position to the closed position. The engagement between the third cam surface and the third jaw surface by the backward movement of the first actuator from the third position to the fourth position causes the first jaw to move in a parallel direction away from the second jaw from the closed position to the clamped position, according to claim 1.

3. The surgical instrument according to claim 1, further comprising a biasing mechanism configured to bias the first jaw toward the open position.

4. The surgical instrument according to claim 3, wherein the biasing mechanism is configured to apply a force that causes the first jaw to move in parallel.

5. The surgical instrument according to claim 3, wherein the biasing mechanism is configured to apply a rotational force to the first jaw.

6. A pin positioned on either the first jaw or the second jaw, The present invention further comprises an elongated slot located on the other of the first jaw or the second jaw, The surgical instrument according to claim 1, wherein the pin and the elongated slot are configured to allow the pivot axis of the first jaw to move in parallel between a first position and a second position different from the first position.

7. A second actuator, wherein the first actuator and the second actuator are located on opposite sides of the vertical axis of the surgical instrument, The surgical instrument according to claim 1, further comprising a translation member disposed between the first actuator and the second actuator.

8. The surgical instrument according to claim 7, wherein the parallel movement member is equipped with a cutting mechanism.

9. The surgical instrument according to claim 2, characterized in that the first jaw surface, the second jaw surface, and the third jaw surface are closer to the posterior end of the first jaw than to the tip of the first jaw.

10. The surgical instrument according to claim 2, wherein the first jaw surface is located at the posterior end of the first jaw, and the second jaw surface and the third jaw surface are located between the posterior and posterior ends of the first jaw.

11. The surgical instrument according to claim 2, wherein the first jaw surface, the second jaw surface, and the third jaw surface define a space for housing the portion of the first actuator.

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