Mechanical joint and related systems and methods

Abstract

To solve one or more problems with the prior art.SOLUTION: A surgical instrument may comprise a shaft comprising a wrist at a first end, an end effector coupled to the wrist, and an actuation element that extends along the shaft and the wrist. The actuation element may follow a twisted path along at least a portion of the wrist. The twisted path may have an angular extent of less than 360 degrees along an entire length of the wrist. A method of configuring a surgical instrument wrist is also contemplated, as well as a support structure for actuation of a surgical instrument. The support structure may comprise at least one passage defining a twisted path about a longitudinal axis of the support structure. The passage may have an angular extent of less than 360 degrees from a first end of the passage to a second end of the passage.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] (Reference to Related Application) This application claims the benefit of U.S. Provisional Application No. 61 / 943,084, filed February 21, 2014, the entire contents of which are incorporated herein by reference.

[0002] The present disclosure relates to mechanical joint structures and instruments and methods that utilize actuation elements to articulate a mechanical joint, particularly aspects of the present disclosure relate to surgical instruments and methods that utilize remotely actuable mechanical joints. [Background technology]

[0003] Remotely controlled surgical instruments, including teleoperated surgical instruments, are often used in minimally invasive medical procedures. During a medical procedure, a surgical instrument may be articulated in one or more directions. For example, a surgical instrument may be actuated by a transmission mechanism at a proximal end of a surgical instrument shaft to orient and position an end effector disposed at a distal end of the surgical instrument at a desired location. The surgical instrument may further include a wrist, such as an articulated and articulatable structure, to which the end effector is connected such that the end effector may be positioned relative to the shaft. The surgical instrument may further include one or more end effector actuating elements that pass through the surgical instrument, including the wrist, to actuate the end effector. Articulating (bending) the wrist may result in bending of the end effector actuating element(s), which may result in a change in length of the end effector actuating element(s). Such a change in length may cause unintended movement of the end effector. In light of this, it may be desirable to provide a surgical instrument that includes one or more end effector actuating elements that are configured to substantially conserve the length of the actuating elements when the wrist of the instrument is articulated. Summary of the Invention [Problem to be solved by the invention]

[0004] Exemplary embodiments of the present disclosure may solve one or more of the problems set forth above and / or demonstrate one or more of the desired features set forth above. Other features and / or advantages may become apparent from the following description. [Means for solving the problem]

[0005] According to at least one exemplary embodiment, a surgical instrument may include a shaft including a wrist at a first end, an end effector coupled to the wrist, and an actuating element extending along the shaft and the wrist. The actuating element may follow a twisted path along at least a portion of the wrist. The twisted path may have an angular extent of less than 360 degrees along the entire length of the wrist.

[0006] According to another exemplary embodiment, a support structure for an actuation element of a surgical instrument may include at least one passageway defining a torsional path about a longitudinal axis of the support structure. The passageway may have an angular extent of less than 360 degrees from a first end of the passageway to a second end of the passageway.

[0007] According to another exemplary embodiment, a method of configuring a surgical instrument wrist may include extending an actuating element along a wrist such that the actuating element follows a twisting path along at least a portion of the wrist, the twisting path may have an angular extent of less than 360 degrees.

[0008] Additional objects, features, and / or advantages will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the present disclosure and / or claims. At least some of these objects and advantages may be realized and obtained by means of the elements and combinations particularly pointed out in the appended claims.

[0009] Both the foregoing general description and the following detailed description are exemplary and illustrative only and are not intended to limit the scope of the claims. Rather, the claims are entitled to their full breadth, including equivalents.

[0010] The present disclosure can be understood from the following detailed description alone or in conjunction with the accompanying drawings, which are included to provide a further understanding of the present disclosure, and are incorporated in and constitute a part of this specification, illustrating one or more exemplary embodiments of the present teachings and, together with the description, serve to explain certain principles and operations. [Brief description of the drawings]

[0011] [Figure 1] 1 illustrates a teleoperated surgical system according to an exemplary embodiment.

[0012] [Diagram 2] 1 illustrates a schematic perspective view of a single flexible bendable member in a straight configuration according to an exemplary embodiment.

[0013] [Diagram 3] 3 shows the member of FIG. 2 in a bent configuration.

[0014] [Figure 4] 3 shows the member of FIG. 2 in a bent configuration.

[0015] [Diagram 5] 1A-1C are partial schematic perspective cross-sectional views of an exemplary embodiment of a surgical instrument shaft and components extending therethrough.

[0016] [Figure 6] 1 is a schematic top view of an exemplary embodiment of a wrist of a surgical instrument;

[0017] [Figure 7] 1 is a schematic top view of an exemplary embodiment of a wrist of a surgical instrument;

[0018] [Figure 8] 1 is a side view of a distal portion of a surgical instrument according to an exemplary embodiment.

[0019] [Figure 9] FIG. 1 is a side view of an exemplary embodiment of a wrist of a surgical instrument.

[0020] [Figure 10A] 1 illustrates a schematic cross-sectional view of a wrist in accordance with an exemplary embodiment;

[0021] [Figure 10B] 1 illustrates a schematic cross-sectional view of a wrist in accordance with an exemplary embodiment;

[0022] [Figure 11] 1 shows a top view that illustrates a schematic of the shape of the actuation element along the wrist.

[0023] [Figure 12A] 1 shows a schematic cross-sectional view of a wrist of a surgical instrument according to an exemplary embodiment;

[0024] [Figure 12B] 1 shows a schematic cross-sectional view of a wrist of a surgical instrument, according to an exemplary embodiment.

[0025] [Figure 13] 13A-13C show top views that diagrammatically illustrate the shape of actuation elements along the wrist.

[0026] [Figure 14A] 1 shows a schematic cross-sectional view of a wrist of a surgical instrument according to an exemplary embodiment;

[0027] [Figure 14B] 1 shows a schematic cross-sectional view of a wrist of a surgical instrument according to an exemplary embodiment;

[0028] [Figure 14C] 1 shows a schematic cross-sectional view of a wrist of a surgical instrument according to an exemplary embodiment;

[0029] [Figure 14D] 1 shows a schematic cross-sectional view of a wrist of a surgical instrument according to an exemplary embodiment;

[0030] [Figure 15] 1 shows a top view that illustrates a schematic of the shape of the actuation element along the wrist.

[0031] [Figure 16A] 1 shows a schematic cross-sectional view of a wrist of a surgical instrument according to an exemplary embodiment;

[0032] [Figure 16B] 1 shows a schematic cross-sectional view of a wrist of a surgical instrument according to an exemplary embodiment;

[0033] [Figure 16C] 1 shows a schematic cross-sectional view of a wrist of a surgical instrument according to an exemplary embodiment;

[0034] [Figure 16D] 1 shows a schematic cross-sectional view of a wrist of a surgical instrument according to an exemplary embodiment;

[0035] [Figure 17] 1 shows a top view that illustrates a schematic of the shape of the actuation element along the wrist.

[0036] [Figure 18] 1 illustrates a perspective view of a distal portion of a surgical instrument shaft according to an exemplary embodiment.

[0037] [Figure 19] 1 shows a schematic perspective view of an actuation element support and a push / pull actuation element according to an exemplary embodiment.

[0038] [Figure 20] FIG. 1 is a side view of an end effector in a closed configuration according to an exemplary embodiment.

[0039] [Figure 21] 21 illustrates the end effector of FIG. 20 in an open configuration.

[0040] [Figure 22] 1 illustrates an end view of an end face of an actuation element support according to an exemplary embodiment.

[0041] [Figure 23] 1 illustrates an end view of an end face of an actuation element support according to an exemplary embodiment.

[0042] [Figure 24] 1 is a perspective view of components of a distal portion of a surgical instrument according to an exemplary embodiment; FIG.

[0043] [Diagram 25] FIG. 25 is a cross-sectional view taken along line 25-25 in FIG.

[0044] [Figure 26] FIG. 2 is an exploded view of an actuation element support according to an exemplary embodiment.

[0045] [Figure 27] FIG. 2 is a schematic perspective view of an actuation element support according to an exemplary embodiment.

[0046] [Figure 28] 1A-1C are side views of an exemplary embodiment of an actuation element including a rigid section.

[0047] [Figure 29] FIG. 29 is an enlarged view of a portion of FIG. 28.

[0048] [Diagram 30] 1 is a side cross-sectional view of an actuation element support and an actuation element according to an exemplary embodiment.

[0049] [Diagram 31] FIG. 2 is a partial perspective view of an exemplary embodiment of a flexible shaft.

[0050] [Diagram 32] FIG. 2 is a perspective end view of an actuation support element and actuation element including coaxial flexible tubes according to an exemplary embodiment.

[0051] [Diagram 33] 1 is a perspective view of a twisted shape and a projection of the angular extent of the twisted shape in accordance with an exemplary embodiment; FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0052] This description and the accompanying drawings illustrating exemplary embodiments should not be understood as limiting. Various mechanical, compositional, structural, electrical, and operational changes, including equivalents, may be made without departing from the scope of this description and the claims. In some cases, well-known structures and techniques have not been shown or described in detail so as not to obscure the disclosure. Like numbers in two or more drawings indicate identical or similar elements. Furthermore, elements and their associated configurations described in detail with reference to one embodiment may, to the extent practical, be included in other embodiments where they are not specifically shown or described. For example, if an element is described in detail with reference to one embodiment and not described with reference to a second embodiment, the element may nevertheless be claimed as being included in the second embodiment.

[0053] For purposes of this specification and the appended claims, unless otherwise indicated, amounts, percentages or ratios, and other numerical values ​​used in the specification and claims should be understood in all instances to be modified by the term "about," unless they are already so modified. Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and appended claims are approximations that may vary depending on the desired properties sought to be obtained. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter should at least be construed in light of the number of published significant digits and by applying ordinary rounding techniques.

[0054] As used in this specification and the appended claims, the singular form and the use of the singular of any term includes plural referents unless expressly and unambiguously limited to one referent. As used herein, the term "comprises" and its grammatical variations are intended to be open-ended, such that the reference to items in a list does not exclude other equivalent items that may be substituted for or in addition to the listed items.

[0055] Moreover, the terminology of this description is not intended to limit the disclosure or the claims. For example, spatially relative terms such as "beneath," "below," "lower," "above," "upper," "proximal," "distal," and the like may be used to describe the relationship of one element or feature to other elements or features in the drawings. These spatially relative terms are intended to include different positions (i.e., locations) and orientations (i.e., rotational orientations) of the device during use or operation in addition to the position and orientation shown in the drawings. For example, if the device in the drawings were inverted, an element or feature described as "beneath" or "below" another element would be "above" or "over" the other element or feature. Thus, the exemplary term "below" can encompass both "above" and "below" positions and orientations. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptions used herein interpreted accordingly.

[0056] According to various exemplary embodiments, the present disclosure contemplates a surgical instrument for a teleoperated surgical system that utilizes an actuating element, at least a portion of which is disposed along a twisted path. The actuating element may be used to actuate an end effector, to articulate a wrist, or to actuate other components. Additionally, the exemplary embodiments may apply to any actuating element that is offset from a central longitudinal axis (neutral axis) of the surgical instrument. According to exemplary embodiments, the twisted path may have an angular extent of less than 360 degrees relative to a centerline of the wrist along the entire length of the wrist. According to exemplary embodiments, at least a portion of the actuating element may be disposed along a twisted path such that the length of the actuating element is conserved at each joint of the wrist as the wrist actuates or bends. By maintaining the length of the actuating element, changes in the length of the actuating element that may otherwise occur during bending of the wrist and that may interfere with the actuating function of the actuating element may be minimized or eliminated. According to an exemplary embodiment, the actuating elements may be positioned along a torsion path such that the length of the actuating elements is maintained at each individual joint of the wrist but not at other individual joints of the wrist, and the entire torsion path of the actuating elements is a length conservative structure.

[0057] The present disclosure further contemplates an actuating element support. The actuating element support may be used to shape at least a portion of the actuating element into a desired shape, for example along a torsional path, to maintain the length of the actuating element and / or increase the buckling strength of the actuating element. According to an exemplary embodiment, the actuating element support may be a one-piece molded part including at least one lumen, at least a portion of the lumen having a torsional shape. According to an exemplary embodiment, the actuating element support may include at least one rigid portion. The actuating element support may include, for example, a plurality of coaxial tubes, according to an exemplary embodiment. According to an exemplary embodiment, the actuating element support may include a tube with one or more material weakened areas, such as notched grooves, to provide flexibility to the support. The actuating element may include a hollow structure, such as a flexible shaft, useful for both pushing and pulling movements, according to an exemplary embodiment. The flexible shaft may be, for example, a wound spring connected to a filament. According to other exemplary embodiments, the flexible shaft may include multiple layers of wound filaments connected to one another.

[0058] 1, an example of a teleoperated surgical system 100 that may utilize surgical instruments according to embodiments described herein is shown. The system 100, which may be, for example, the da Vinci® Surgical System available from Intuitive Surgical, Inc., includes a patient side cart 102 having a number of surgical instruments 140, each mounted within a docking port on an arm 110. The instruments 140 may be interchangeable such that the instruments 140 mounted on the arm 110 may be selected for a particular medical procedure or may be replaced during a medical procedure to provide a desired clinical function. As is well known in the art, the surgical instruments 140 may perform many functions, including, but not limited to, forceps or graspers, needle drivers, scalpels, scissors, cauterizing tools, and staplers.

[0059] Each instrument 140 generally includes a transmission or back-end mechanism 150, a main shaft 160 extending from the transmission mechanism 150, an optional wrist (not shown in FIG. 1 ) at the distal end of the main shaft 160, and an end effector 180 extending from the wrist or directly from the main shaft 160. For example, FIG. 8 illustrates one exemplary embodiment of a distal end of a surgical instrument including, among other things, a shaft 251, a wrist 250 at the distal end of the shaft 251, and an end effector 252 extending from the wrist 250. An actuating element 354, such as, for example, a tendon or rod, may extend through the shaft 251 to the wrist 250 and / or to the end effector 252. As one of ordinary skill in the art would be familiar with, the actuating element may be configured as a pull / pull or push / pull actuating element. Exemplary embodiments of pull / pull and push / pull actuation devices are described in U.S. Patent No. 8,545,515, issued Oct. 1, 2013, which is incorporated herein by reference in its entirety. Thus, the actuation element 254 may be used to actuate the wrist 250 and / or the end effector 252. Thus, with reference to FIG. 1 , the actuation element may extend from a transmission 150, which may be connected to the patient side manipulator 112. The transmission 150 typically provides a mechanical linkage of the actuation element to drive a motor in the patient side cart 102. For example, the transmission 150 may be configured to be connected to the patient side manipulator 112 of the arm 110 of the patient side cart 102. As a result, the patient side manipulator 112 and the transmission 150 may be used to apply a force to the actuation element 254 to actuate the wrist 250 and / or the end effector 252. Additionally, referring back to FIG. 8, electrical conductors (not shown in FIG. 8) may extend through shaft 251 and wrist 250 to end effector 252 .

[0060] Thus, the system 100 can control the movement and force along the actuation elements as needed to move or position the wrist and manipulate the end effector 180. The arms 110 of the patient side cart 102 can be used to insert the end of the surgical instrument 140 through a cannula in a small incision in a patient undergoing a medical procedure, as well as to manipulate the wrist and / or end effector 180 of the instrument 140 at a work site inside the patient.

[0061] The camera instrument 104 may be similarly mounted to an arm 110 of the patient side cart 102 and may optionally also have a wrist that the system 100 operates to position the distal end of the camera system 104 to view the work site and the operation of the surgical instrument within the patient. A view from the camera system 104, which may be stereoscopic or three-dimensional, may be viewed from a control console (not shown) and images may be displayed on a monitor 106. Thus, the processing system of the system 100 may provide a user interface that allows a doctor or other medical personnel to view the camera system 104 and navigate the instrument 140. For example, similar to the surgical instrument 140, the arm 110 may be used to insert the end of the camera instrument 104 through a cannula in a small incision in a patient undergoing a medical procedure, and to manipulate the wrist and / or end effector 180 at the work site inside the patient.

[0062] The diameter or diameters of the main shaft 160, wrist, and end effector 180 are generally selected according to the size of the cannula with which the instrument will be used. In an exemplary embodiment, the diameter of the camera instrument 104 and the diameter of the wrist and main shaft 160 may range from about 3 mm to about 13 mm. For example, the diameters may be about 4 mm, about 5 mm, about 8 mm, about 10 mm, or about 13 mm to match the size of some existing cannula systems.

[0063] As illustrated in the schematic diagram of FIG. 1, the teleoperated surgical system 100 may further include a surgeon console 120 and an auxiliary control / vision cart 130. In general, the surgeon console 120 serves as a master controller that receives input from a user, e.g., a surgeon, via various input devices, including but not limited to a gripping mechanism 122 and foot pedals 124, and responds to implement desired movements of the surgical instrument(s) 102 and, correspondingly, to accomplish the desired surgical procedure. For example, but not limited to, the gripping mechanism 122 may act as a "master" device that may control the surgical instrument 140 and / or the camera instrument 104, which may act as corresponding "slave" devices on the arm 10. For example, but not limited to, the gripping mechanism 122 may control the wrist and / or end effector 180 of the surgical instrument 140, as will be familiar to those skilled in the art. Additionally, the foot pedal 124 may be depressed, for example, but not limited to, to deliver monopolar or bipolar electrosurgical energy or to activate various other functions of the instrument 140 (e.g., suction, irrigation, and / or various other flux delivery modes). In other words, based on commands provided to an input device, for example, at the Surgeon Console 120, the Patient Side Cart 102 may position the instruments 140, 104 to perform the desired medical procedure via the Patient Side Manipulator 112 on the arm 110. Thus, the instruments 140, 104 on the Patient Side Cart 102 may be remotely operated according to commands input by a user at the Surgeon Console 120. The Surgeon Console 120 may further include a display to enable the surgeon to view a three-dimensional image of the surgical site, for example, via the camera instrument 104 on the Patient Side Cart 102, during the surgical procedure.

[0064] In a non-limiting embodiment of the teleoperated surgical system, the control / vision cart 130 includes a “core” processing device, such as a core processor 134 and / or other ancillary processing devices, that may be incorporated into or physically supported by the control / vision cart 130. The control / vision cart 130 may also include other controls that operate the surgical system. In an exemplary embodiment, signal(s) or input(s) from the surgeon console 120 may be sent to one or more processors in the control / vision cart 130, which may interpret the input(s) and generate command(s) or output(s) to be sent to the patient side cart 102 to effectuate the manipulation of one or more of the surgical instruments 140, 104 and / or the arms 110 that couple the surgical instruments 140, 104 to the patient side cart 102. The system components in FIG. 1 are not shown in any particular orientation and may be positioned as desired such that the patient side cart 102 is positioned relative to the patient to affect surgery on the patient.

[0065] A surgical instrument may have one or more degrees of freedom that allow the surgical instrument to bend in one or more directions. For example, a wrist may provide joint actuation that allows bending in one or more directions, such as in any pitch and yaw directions that are substantially orthogonal to one another. A surgical instrument may include other joints that allow bending, such as the joggle joint described in U.S. Patent No. 7,942,868, published May 17, 2011, and U.S. Patent Application Publication No. 2008 / 0065105, published March 13, 2008, both of which are incorporated herein by reference in their entirety. Elements that go through the bending portion of the surgical instrument, including actuation elements (e.g., tendons or rods) and cables, may also bend to actuate the wrist or end effector.

[0066] Bending can have an effect on the actuating elements as they travel through a bending portion of a surgical instrument. Referring to FIG. 2, a schematic perspective view of a single flexible member 200 that can bend like an articulation is shown. A first actuating element 202 and a second actuating element 204 extend through the member 200 along a longitudinal axis 208 of the member 200. In the exemplary embodiment of FIG. 2, where the member 200 is in a straight (neutral) configuration, a bending axis 206 travels through each of the first actuating element 202 and the second actuating element 204. As shown in FIG. 3, when the member 200 is bent about the bending axis 206, the first and second actuating elements 202, 204 also bend. Because the axis 206 travels through both the actuating elements 202, 204, there is no relative change in length between the first actuating element 202 and the second actuating element 204. In other words, one of the actuating elements 202, 204 is not substantially longer or substantially shorter than the other.

[0067] 2, a second bending axis 207 for member 200 passes between first actuating element 202 and second actuating element 204. As a result, member 200 is bent in the manner shown in FIG. 4 about bending axis 207, with first actuating element 202 being stretched relative to its neutral position, causing a positive change in its length, while second actuating element 204 is compressed relative to its neutral position, causing a negative change in its length. Thus, bending member 200 about bending axis 207 may cause a change in the relative lengths of actuating elements 202, 204, such that one actuating element is longer than the other. Such a relative change in length may interfere with the function of the actuating elements to actuate an end effector. For example, when the actuating elements 202, 204 are used to open and close an end effector by applying tension or compression to the actuating elements 202, 204, a relative change in length between the actuating elements 202, 204 will create slack in one of the actuating elements 202, 204, reducing the ability of the actuating element to transmit the desired tension or compression to result in the desired actuation of the end effector.

[0068] In light of these considerations, it may be desirable to design the joints of a surgical instrument such that the bending axis of the joint extends through the actuation element. For example, a single actuation element may be provided to actuate the end effector, with the single actuation element extending along the center of the surgical instrument. In such a configuration, bending axes that are substantially perpendicular to each other may run through the center of the instrument and the actuation element to provide two degrees of freedom for bending the surgical instrument. As a result, the length of the actuation element does not substantially change when the surgical instrument is bent about either bending axis. However, while this approach may be useful when a single actuation element is sufficient to control the end effector, a surgical instrument may include multiple actuation elements to actuate different components of the instrument or to actuate an end effector or wrist that requires more than one actuation element.

[0069] 5 illustrates an example of a surgical instrument 220 including multiple actuating elements. In various exemplary embodiments, the surgical instrument 220 may be a surgical instrument configured according to exemplary embodiments described in U.S. Patent Application Publication Nos. 2012 / 0215220, published August 23, 2012, 2012 / 0310254, published December 6, 2012, and 2012 / 0310221, published December 6, 2012, each of which is incorporated by reference in its entirety. As illustrated, the surgical instrument 220 includes a first component actuating element 222 extending along a centerline 221 of the surgical instrument 220. The first actuating element 222 may be configured to actuate a cutting blade 227 or other component, for example, by pushing or pulling the cutting blade along the centerline 221.

[0070] Because the first actuating element 222 is disposed along the centerline 221, both the pitch axis 228 and the yaw axis 229 of the instrument 220 pass through the first actuating element 222. As a result, the first actuating element 222 does not undergo substantial change in length when the surgical instrument 220 is bent about the axis 228 or the axis 229. The surgical instrument 220 also includes other actuating elements, such as, for example, second and third end effector actuating elements 224, 226, which actuate an end effector (not shown) of the instrument 220. The end effector may be, for example, a forceps or grasper, a needle holder, a scalpel, scissors, a cautery tool, a staple, or other types of end effectors used in the art, such as a jawed end effector. According to an exemplary embodiment, the actuating elements 224, 226 may be pull / pull actuating elements that open and close the end effector by extending one of the actuating elements 224, 226 and pulling the other of the actuating elements 224, 226, as will be familiar to those skilled in the art. The surgical instrument 220 may include additional lumens 223, 225 for additional actuating elements or other components, such as flux conduits, for example, conduits for providing electrosurgical energy or other flux supplies to the end effector.

[0071] Due to the presence of the first actuating element 222, the actuating elements 224, 226 cannot be disposed along the centerline 221 and the shaft 228 does not pass through the actuating elements 224, 226. Thus, when the surgical instrument 220 is bent relative to the shaft 228, length changes can occur between the actuating elements 224, 226. Because of these length changes of the actuating elements 224, 226 during bending, greater mechanical complexity is required to decouple the actuating elements 224, 226 from one another for actuation of the end effector.

[0072] In light of these considerations, the present disclosure contemplates a surgical instrument having one or more actuating elements that exhibit substantially no change in overall length during bending, even when the actuating element is offset from the bending axis. When the change in overall length of the actuating element during bending is minimal, the mechanical complexity of the instrument including the actuating element may be reduced. Additionally, by making the actuating element not substantially change its overall length due to bending (in other words, maintaining the length of the actuating element), the actuating element may be decoupled from the movement of the joint through which it extends. In other words, bending of the actuating element does not cause undesired or unintended actuation of the end effector, regardless of articulation of such joint.

[0073] One way to minimize or prevent overall change in working length due to bending is to position the working element along a twisted path as it travels through a bent portion of the surgical instrument. For example, the working element may be positioned along a twisted path that has an angular extent of 360° for each bend axis that the working element travels through to substantially minimize or prevent change in the overall length of the working element (i.e., to maintain the length of the working element).

[0074] 6, a schematic diagram of an exemplary embodiment of a wrist 230 of a surgical instrument is shown, including a first actuating element 232 and a second actuating element 234. Wrist 230 may include a joint (not shown in the schematic diagram of FIG. 6) to cause bending of wrist 230 about bending axis 236 (extending into and out of the plane of FIG. 6). Wrist 230 is bent about bending axis 236, causing portions of actuating elements 232, 234 above longitudinal axis 238 in FIG. 6 to undergo a positive change in length and portions below longitudinal axis 238 to undergo a negative change in length. Because actuating elements 232, 234 are disposed along a torsional path having an angular extent of 360° about axis 238 through wrist 230, actuating elements 232, 234 do not undergo substantially any change in length due to bending wrist 230 about axis 238. For example, the portion of actuating element 232 in zone 231 undergoes a positive length change, while the portion of actuating element 232 in zone 233 undergoes a negative length change that effectively cancels the positive length change of zone 231. Similarly, the negative length change of actuating element 232 in zone 235 is canceled by the positive length change of actuating element 232 in zone 237. A similar cancellation of length changes between zones 231, 233, 235, and 237 occurs for actuating element 234, but in the opposite manner, because actuating element 234 is positioned opposite actuating element 232 about axis 238.

[0075] 7, a schematic diagram of another exemplary embodiment of a wrist 240 including a first actuating element 242 and a second actuating element 244 is shown, where the wrist 240 is bent about a bending axis 246. Similar to the exemplary embodiment of FIG. 6, the wrist 240 may include joints (not shown in the exemplary embodiment of FIG. 7) to cause bending of the wrist 240 about the bending axis 246. In the exemplary embodiment of FIG. 7, at the ends of zones 245, 247 of the wrist 240, the actuating elements 242, 244 are positioned along a neutral axis 248 instead of being offset from the neutral axis as in the exemplary embodiment of FIG. 6. However, the actuating elements 242, 244 are offset from the longitudinal axis 248 in zones 241 and 243 and are positioned along a torsional path. As the actuating elements 242, 244 progress through the wrist 240, the overall length of the actuating elements 242, 244 does not change substantially because the actuating elements 242, 244 are disposed along a torsional path having an angular extent of 360°. For example, the portion of the actuating element 242 in zone 241 undergoes a positive change in length, while the portion of the actuating element 242 in zone 243 undergoes a negative change in length that offsets the positive change in length. The actuating element 244 undergoes a similar offset of the change in length, but in the opposite manner. The portions of the actuating elements 242, 244 in zones 245, 247 do not undergo any significant change in length relative to one another along the longitudinal axis 248.

[0076] As discussed above with respect to the exemplary embodiment of Figures 6 and 7, the actuating elements that are offset from the central longitudinal axis (neutral axis) of the surgical instrument may be arranged along a torsion path that has an angular extent of 360° about a bending axis of the surgical instrument. However, a surgical instrument may include several bending axes. For example, the wrist of a surgical instrument may include one or more multi-DOF (degree of freedom) joints and thus may include multiple bending axes. For example, if the wrist 230 of the exemplary embodiment of Figure 6 includes multiple bending axes 236 that extend in substantially the same direction, the actuating elements 232, 234 may be arranged along a torsion path that has an angular extent of 360° about both bending axes instead of only one bending axis.

[0077] According to another exemplary embodiment, where the wrist includes a first plurality of bending axes extending in one direction, such as in the direction of bending axis 236 of FIG. 6, and a second plurality of bending axes extending in another direction, such as substantially perpendicular to bending axis 236 of FIG. 6, the actuating element may be disposed along a twist path having an angular extent of 360° across the first plurality of bending axes, as well as along a twist path having an angular extent of 360° across the second plurality of bending axes. However, twisting of the actuating element along a twist path that results in minimal or no length change for each bending axis (e.g., when the bending axes extend in different or alternating directions) may result in increased friction between the twisted actuating element and the surfaces that support and / or guide the actuating element into the twisted shape. Friction between the actuating element and its supporting surface may be increased by:

number

[0078] Various exemplary embodiments useful for providing length maintenance of actuating elements are contemplated by the present disclosure and are discussed in more detail below with respect to articulated structures of surgical instruments. Various articulated structures may employ actuating element configurations that follow a torsional path. For example, the articulated structure may be for a wrist, such as a wrist configured in accordance with exemplary embodiments of U.S. Provisional Application No. 61 / 943,068, entitled "Mechanical Wrist Joints with Enhanced Range of Motion, and Related Devices and Methods," filed February 21, 2014 under Attorney Docket No. ISRG04480PROV / US, and International Application No. PCT / US15 / xxxxxx (ISRG04480 / PCT), which claims priority to and was filed on the same day as U.S. Provisional Application No. 61 / 943,068, each of which is incorporated herein by reference in its entirety. In other embodiments, the articulated structure may be used in a joggle joint, such as the joggle joint described in U.S. Pat. No. 7,942,868 published May 17, 2011 and U.S. Patent Application Publication No. 2008 / 0065105 published March 13, 2008.

[0079] Another type of joint that may utilize the exemplary embodiments of the present disclosure is shown in the exemplary embodiment of FIG. 8. As mentioned above, FIG. 8 shows a wrist 250 connected to an end effector 252. The end effector 252 may include, for example, a clevis and jawed member 255 according to an exemplary embodiment. According to an exemplary embodiment, the wrist 250 includes a first link 256 connected to the end effector 252 and a second link 258, with a joint 270 connecting the first link 256 to the end effector 252 and a joint 269 connecting the second link 258 to the first link 256. As one skilled in the art would be familiar with, the links in the various exemplary embodiments described herein may be configured as disks. However, other shapes may be utilized without departing from the scope of the disclosure and claims. According to another exemplary embodiment in which the end effector 252 is directly joined to the first link 256 via a joint 270, at least a portion of the end effector 252 is part of the wrist 250.

[0080] According to other exemplary embodiments, the wrist may include three links instead of two links. For example, instead of having link 256 directly connected to clevis 253 to provide a joint 270 between link 256 and clevis 253 as shown in the FIG. 8 exemplary embodiment, a third link may be provided between link 256 and clevis 253, with joint 270 formed between link 256 and the third link, and the third link attached to clevis 253.

[0081] The first link 256 and the clevis link 253 may be articulated to one another about an axis 260 (extending into and out of the plane of FIG. 8 ) in a direction 261. The wrist 250 further includes a second link 258 connected to the first link 256 such that the second link 258 and the first link 256 may be articulated to one another about an axis 262 in a direction 263. The axes 260, 262 may be substantially orthogonal to one another to provide the wrist 250 with two degrees of freedom, such as movement in arbitrarily selected pitch and yaw directions. Because the wrist 250 has two degrees of freedom with movement in different directions, the wrist 250 may be described as an “AB” wrist, which refers to the two different movements provided by the joints 269, 270 of the wrist 250.

[0082] The exemplary embodiments described herein may be used in wrists other than the "AB" type wrist. For example, a wrist may include multiple joints of the same bending axis type, which may provide a wider range of wrist motion. Referring to FIG. 9, an exemplary embodiment of wrist 280 is shown, including links 281-285. Links 281 and 282 are connected such that they may articulate with each other about axis 290 in direction 291. Links 284 and 285 are connected to each other in substantially the same manner as links 281 and 282, and links 284 and 285 articulate with each other about axis 296 in direction 297. Thus, the joint 300 between links 281 and 282 and the joint 306 between links 284 and 285 are of the same type, and may be referred to as the "A" joint. Links 282 and 283 are connected such that they may articulate with each other about axis 292 (extending into and out of the plane of FIG. 9) in direction 293. Axes 290, 292 may be substantially orthogonal to one another to provide wrist 280 with two degrees of freedom, such as movement in any pitch and yaw (or A and B) directions. Additionally, links 283 and 284 are connected to one another in substantially the same manner as links 282 and 283, and links 283 and 284 are articulated to one another about axis 294 (extending into and out of the page of FIG. 9 ) in direction 295. Joint 302 between links 282 and 283 and joint 304 between links 283 and 284 are of the same type and may be referred to as a "B" joint. Wrist 280 may be referred to as an "ABBA" wrist, referring to the ordering of the bending axis types of the joints along wrist 280.

[0083] In other examples, the wrist may have an "ABAB" configuration. Such a configuration may include two "AB" joints, such as links 256, 258 in the exemplary embodiment of FIG. 8 in series such that the two "AB" joints are directly joined to each other in the "ABAB" configuration.

[0084] Due to the various complex components of the wrist, which may have different motions in different directions, and the small size of the wrist for a surgical instrument, various problems in threading the working elements through the wrist arise, including determining how to thread the working elements through the wrist to minimize how far the working elements extend through the wrist in a twisted configuration while substantially maintaining the length of the working elements as the wrist is bent. Various exemplary embodiments herein contemplate a wrist of a surgical instrument in which one or more working elements extend along a twisted path having an angular extent of less than 360° along the entire length of the wrist. These designs take into account, among other things, for example, the angular extent that the actuating element traverses along the torsion path over the length of the wrist, the angular extent that the actuating element traverses along the torsion path over each bending axis, the angular extent that the actuating element traverses and the resulting friction between the actuating element and the support surface(s) (i.e., minimizing the angular extent minimizes the amount of friction that must be overcome, like a capstan equation, when applying a force to actuate the actuating element), and the initial angle of the actuating element relative to the bending axis.

[0085] 10A and 10B, schematic cross-sectional views of two joints 1000A and 1000B of a wrist are shown. According to an exemplary embodiment, the wrist may be configured similarly to the wrist 250 of the exemplary embodiment of FIG. 8. For example, the cross-sections of the joints 1000A and 1000B in FIG. 10A and 10B may be schematic views taken along lines AA and BB of the exemplary embodiment of the AB wrist of FIG. 8, but modified to show the amount of twisting of the actuating elements 316A, 316B as they extend across each of the joints 1000A and 1000B. The actuating elements 316A, 316B may be used, for example, to actuate an end effector (such as the end effector 252 of the exemplary embodiment of FIG. 8) or to actuate other components of the instrument, such as, for example, a wrist. According to an exemplary embodiment, the actuation elements 316A, 316B may follow a twisted path such that actuation of the actuation elements 316A, 316B does not result in reversed motion, such as when the actuation elements 316A, 316B are used to actuate a wrist.

[0086] The cross sections of Figures 10A and 10B respectively present two different joints of the wrist 1000A and 1000B, with a cross section for joint 1000A presenting a joint (such as joint 269 in the exemplary embodiment of Figure 8) having a bending axis 312 and a cross section for joint 1000B presenting a joint (such as joint 270 in the exemplary embodiment of Figure 8) having a bending axis 322.

[0087] The actuating elements of various exemplary embodiments described herein may be substantially length conservative. Thus, in some cases, the actuating element may have zero change in length when the joint(s) through which the actuating element extends, such as one or more joints of a wrist, is actuated, while in some cases the actuating element may undergo a small amount of length change. According to exemplary embodiments, a substantially length conservative actuating element may undergo a change in length of, for example, less than about 0.010 inches (0.0254 centimeters), including no change in length, when a stress of less than 10 pounds (4.536 kilograms) is applied to the actuating element.

[0088] The angular extent of the twist of the actuating elements 316A, 316B may be selected to make the actuating elements 316A, 316B length-preserving across the wrist. For example, each of the actuating elements 316A, 316B may have a 90° twist for each joint 1000A, 1000B of the wrist, as shown in FIGS. 10A and 10B. In other words, the actuating elements 316A, 316B may have an angular extent of 90° relative to the centerline 318 for each joint 1000A, 1000B. For example, the actuating element 316A may be disposed along a twist path having an angular extent of approximately 90° across the joint 1000A from the initial position 311 to the subsequent position 313. Additionally, the actuating element 316A may be twisted 90° across joint 1000B from an initial position 315 (corresponding to position 313 of the structure in cross section for joint 1000A) to a subsequent position 317.

[0089] To facilitate a view of the twisting of the actuating elements, Fig. 11 shows a schematic top view of a wrist 310 including the joints depicted in Figs. 10A and 10B, with only the actuating element 316A shown along the length of the joints 1000A, 1000B of the wrist 310 to illustrate the shape of the actuating element 316A along the different joints of the wrist 310. In Fig. 11, the wrist 310 is generally segmented into joints 1000A and 1000B to show the amount of twisting of the actuating element 316A along each of the joints 1000A and 1000B. According to an exemplary embodiment, the joint 1000A may have a length 326 and the joint 1000B may have a length 328, which are shown generally in the exemplary embodiment of Fig. 8 for purposes of illustrating the amount of twisting for the joints 1000A and 1000B. With reference to the exemplary embodiment of FIG. 8, joint 1000A may, for example, correspond to joint 269, with the torsion for joint 1000A being substantially centered at joint 269 and extending in substantially equal amounts on either side of joint 269.

[0090] Similarly, referring to the exemplary embodiment of FIG. 8, joint 1000B may correspond to joint 260, for example, with the twist for joint 1000B being substantially centered at joint 270 and extending substantially equal amounts on both sides of joint 270. As shown in FIG. 11, actuating element 316A may twist from initial position 311 to subsequent position 313 across joint 1000A, and from initial position 315 to subsequent position 317 across joint 1000B. According to an exemplary embodiment, the twist of the actuating element may be substantially continuous as actuating element 316A twists across joints 1000A and 1000B, as shown in FIG. 1. Using a substantially continuous twist may beneficially minimize the amount of friction between the actuating element and the support structure, since the twist may occur over a longer longitudinal length of the wrist.

[0091] However, the twisting of the actuating elements is not limited to the substantially continuous twisting shown in the exemplary embodiment of FIG. 11. For example, the actuating elements may be twisted into sections having different amounts of twisting along the length of the actuating elements. In other cases, the actuating elements may instead follow a discontinuous twisting path that includes twisted portions separated by one or more regions in which the actuating elements extend linearly and are substantially parallel to the neutral axis of the wrist. In such discontinuous twisting embodiments, the twisting of the actuating elements 316A, 316B may still be in the amount shown in FIGS. 10A and 10B (i.e., 90°), but may extend over a shorter span of the lengths 326, 328 of the joints 1000A and 1000B in FIG. 11 due to one or more linear, non-twisted portions of the actuating elements 316A, 316B.

[0092] As best shown in FIGS. 10A and 10B, the actuating element 316A is twisted 90° about a neutral axis 318 for each of the joints 1000A and 1000B (i.e., has a twisted shape with an angular extent of 90° relative to the centerline 318 for each of the joints 1000A and 1000B). According to an exemplary embodiment, the neutral axis 318 may be the longitudinal centerline of the wrist 310. Additionally, the axis 318 may be the longitudinal centerline of the wrist 310 according to an exemplary embodiment and may be the centerline for the twisting path followed by the actuating elements 316A, 316B. As shown in the cross-section of the joint 1000B in FIG. 10B, the actuating element 316A may be radially spaced a distance 329 from the neutral axis 318. As shown in the cross-section of joint 1000B in FIG. 10B, actuating elements 316B may also be radially spaced a distance 329 from the neutral axis. The radial distance 329 may vary according to the diameter of the wrist 310. The radial distance 329 may be, for example, greater than about 0 mm to about 10 mm when the actuating elements do not extend along the neutral axis 318 (e.g., are spaced a non-zero radial distance from the neutral axis 318). According to other exemplary embodiments, the radial distance 329 may be, for example, greater than 0 to about 6 mm. According to exemplary embodiments, the radial distance 329 may be maximized such that actuating elements 316A, 316B are spaced at or near the periphery of joints 1000A and 1000B to maximize the interior space within the wrist 310. According to other exemplary embodiments, the radial distance 329 may be minimized such that the actuating elements 316A, 316B are spaced apart near the neutral axis 318, for example, when the actuating elements 316A, 316B and / or the guide lumens for the actuating elements 316A, 316B are difficult to bend.

[0093] Similar to actuating element 316A, actuating element 316B may also be twisted 90° (i.e., have an angular spread of 90° along a twist path about centerline 318) from an initial position 321 to a subsequent position 323 at the joint represented by cross-section 1000A, as shown in Figures 10A and 11. Additionally, actuating element 316B may be twisted 90° from an initial position 325 (which coincides with subsequent position 323 in cross-section 1000B) to a subsequent position 327 at the joint represented by cross-section 1000B, as shown in Figures 10B and 11. Thus, each of the actuating elements 316A, 316B may have a total twist of 180° across the length of the wrist 310 (i.e., an angular spread of 180° along a twist path about the centerline 318) to make the actuating elements 316A, 316B length-maintaining across the wrist 310. This results in an overall twist of each actuating element 316A, 316B that is substantially less than a 360° twist.

[0094] For example, when considering the twisting of the actuating element 316A about the centerline 318, such as when the neutral axis 318 is the origin in a polar coordinate system, the actuating element 316A twists from an initial position 311 at joint 1000A to a subsequent position 317 at joint 1000B through an angular measurement of 180° across the length of the wrist 310. This is further illustrated in the exemplary embodiment of Figure 33, which depicts a twisting path 900. As shown in the exemplary embodiment of Figure 33, the twisting path 900 extends from a first end 902 to a second end 906 in a twisted configuration about a longitudinal axis 908 (i.e., the centerline 908). To illustrate the angular extent of torsional path 900, torsional path 900 may be projected onto plane 901 as an arc 910 having a radius of curvature 913, with points 912 on arc 910 corresponding to locations on torsional path 900. For example, point 912 on arc 910 corresponds to first end 902 of torsional path 900, and point 914 on arc 910 corresponds to point 904, which is approximately halfway along the length of torsional path 900.

[0095] 21 as having a substantially constant radius of curvature 913, the torsional path 900 (and thus the arc 910) may include segments having different curvatures and / or may include one or more straight segments. Thus, when a torsional path is discussed in the exemplary embodiments herein, the torsional path may twist with a substantially continuous radius of curvature or may include segments with different radii of curvature, including curved segments with different radii of curvature and / or straight segments.

[0096] As shown in FIG. 33, the angular extent 920 between points 912 and 914 relative to a centerline 908 (which may also be projected onto plane 901) is approximately 180°. Thus, when discussing the angular extent of the twist path in the exemplary embodiments herein, the angular extent may be determined according to the angular extent 920 relative to centerline 908, as shown in FIG. 33. Furthermore, since twist path 900 completes a full 360° twist from first end 902 to second end 906, point 912 on arc 910 corresponds to both first point 902 and second point 906, and the angular extent 922 between first end 902 and second end 906 is 360°. Thus, in the exemplary embodiment of FIG. 33, arc 910 forms a complete circle. However, in other embodiments in which the twist path is not a full 360° twist, arc 910 does not complete a circle. This is because the angular extent of the twist path is less than 360°.

[0097] Twisting the actuating elements 316A, 316B in the manner shown in Figures 10A, 10B, and 11 may allow the actuating elements 316A, 316B to be length-maintaining about the twist 310. Furthermore, according to an exemplary embodiment, the angular extent of the twist of the actuating elements 316A, 316B may be selected to cause the actuating elements 316A, 316B to be length-maintaining about each of the joints 1000A and 1000B. For example, as shown in the schematic diagram of the exemplary embodiment in Figure 10A, about half of each of the actuating elements 316A, 316B is to the left of the bending axis 312 and about half of each of the actuating elements 316A, 316B is to the right of the bending axis 312 about the joint 1000A. As a result, any positive or negative change in length for the portion of the actuating elements 316A, 316B to the left of the bending axis is offset by any negative or positive change in length for the portion of the actuating elements 316A, 316B to the right of the bending axis 312. Thus, there is no net change in length for the actuating elements 316A, 316B, making each of the actuating elements 316A, 316B length-conserving across the joint 1000A. Similarly, as shown in the schematic diagram of the exemplary embodiment of the joint 1000B in FIG. 10B, for the joint 1000B, approximately half of each actuating element 316A, 316B is on the top side as well as on the bottom side of the bending axis 322, so that any change in length for the top side of the actuating elements 316A, 316B relative to the bending axis 322 is substantially offset by any change in length for the bottom side of the actuating elements 316A, 316B relative to the bending axis 322. Thus, there is substantially no net change in length for the actuating elements 316A, 316B, causing the actuating elements 316A, 316B to be length-maintaining across the joint 1000B.

[0098] The amount of twisting of the actuating member across the joint may also be generally represented by the average angular position of the actuating member across the length of the joint. For example, the average angular position 314 of the actuating element 316A with respect to the neutral axis across the length 326 of the joint 1000A is shown generally in FIG. 10A. In other words, the average angular position 314 of the actuating element 316A may be determined as the actuating element 316A twists through 90° across the length 326 of the joint 1000A, such as when the neutral axis 318 is treated as the origin in a polar coordinate system. When the average angular position 314 of the actuating element 316A across the length 326 of the joint 1000A coincides with the bending axis for the joint 1000A, as shown in FIG. 10A, this indicates that the actuating element 316A is length-constrained for the joint 1000A. 10B, actuating element 316A has an average angular position 324 across the length 328 of joint 1000B that also coincides with bending axis 322. Furthermore, because actuating element 318B is positioned opposite actuating element 316A and is a substantially torsional mirror image of actuating element 316A, the average angular position of actuating element 316B across joints 1000A and 1000B may be considered to be the same as the average angular positions 314, 324 of actuating element 316A.

[0099] As mentioned above, various exemplary embodiments consider the initial angle of the actuating element relative to the bending axis. The initial angle may be considered as the initial angle of the actuating element relative to the bending axis when the actuating element enters the joint. As shown in the exemplary embodiment of FIG. 10A, the actuating element 316A may have an initial angle 319 at its initial position 311 relative to the bending axis 312 at the joint 1000A. According to an exemplary embodiment, the initial angle 319 may be about 45°, especially when the actuating element is twisted 90° along the length 326 of the joint 1000A, such that a substantially equal amount of the actuating element may be positioned on either side of the bending axis 312, as shown in the cross-sectional view of FIG. 10A. The actuating element 316B may be positioned opposite the actuating element 316A across the neutral axis 318, so that the initial position 323 of the actuating element 316B at the joint 1000A may be at substantially the same angle 319, such as about 45°, relative to the bending axis 312. In joint 1000B, the initial position of the actuation elements 316A, 316B may be at an angle relative to the bending axis 322 that is approximately equal to the angle 319 in joint 1000A.

[0100] However, other initial angles may be utilized, for example, when a smaller or larger amount of angular spread (twist) is used across a given joint. For example, the initial position 311 of the actuating element 316A may be at an angle 319 of about 50° relative to the bending axis 312. In such an embodiment, the amount of twist of the actuating element 316A across the joint 1000A may be about 100° such that a substantially equal amount of the actuating element 316A may be positioned on either side of the bending axis 312 and the actuating element 316A is length-constant across the joint 1000A. Other values ​​for the initial angle 319 may be contemplated by exemplary embodiments herein, such as, for example, from about 40° to about 60°, according to exemplary embodiments.

[0101] Various embodiments according to the present invention contemplate other initial position actuating element twist configurations than those shown and discussed with reference to the exemplary embodiment of Figures 10A, 10B, and 11. Referring to Figure 12A, a schematic cross-sectional view of a joint of an exemplary embodiment of a wrist is shown. The joint 1200A depicted in the exemplary embodiment of Figure 12A may be an A-type joint, similar to the exemplary embodiment of Figure 10A, except that the initial positions of the actuating elements 330A, 330B at the joint 1200A are aligned with the bending axis 332A. The actuating elements 330A, 330B may be used, for example, to actuate an end effector (such as the end effector 252 of the exemplary embodiment of Figure 8) or to actuate other components of the instrument, such as, for example, a wrist. According to an exemplary embodiment, the actuation elements 330A, 330B may follow a twisted path such that actuation of the actuation elements 330A, 330B does not result in reverse motion, for example, when the actuation elements 330A, 330B are used to actuate a wrist.

[0102] 12A and 13, the latter of which is a schematic top view of a wrist 320 including the joint depicted in FIGS. 12A and 12B, but showing only the twisting of the actuating element 330A, which does not have a twist along the length 336 of the joint 1200A relative to a longitudinal neutral axis 337. As discussed with respect to FIG. 11, the axis 337 may be a centerline for the wrist 320 and may additionally be a centerline for the twisting paths of the actuating elements 330A, 330B. Thus, the average angular position 334 of the actuating elements 330A, 330B over the length 336 of the joint 1000A (shown diagrammatically in FIG. 13) is aligned with the bending axis 332A (i.e., the bending axis 332A runs through the actuating elements 330A, 330B). As a result, the actuating elements 330A, 330B are already length-maintaining at the joint 1200A and do not need to be twisted at that joint. However, at the joint 1200B, the initial positions 331A, 335A of the actuating elements 330A, 330B, respectively, are offset from the bending axis 332B. For example, the initial positions 331A, 335A of the actuating elements 330A, 330B may be offset from the bending axis 332B by about 90° at the joint 1200B.

[0103] To achieve length maintenance of the actuating elements 330A, 330B across the joint 1200B, the actuating elements 330A, 330B may be twisted over an angular extent of 180° relative to their respective subsequent positions 331B, 335B (i.e., may follow a twisting path over an angular extent of 180° about the centerline 337). As a result, approximately equal amounts of each actuating element 330A, 330B are on either side of the bending axis 332B at the joint 1200B (e.g., on the top and bottom sides in the cross-section of the joint 1200B in FIG. 13B ). This is also demonstrated by the average angular position 339 of the actuating elements 330A, 330B over the length 338 of the joint 1200B (shown diagrammatically in FIG. 13), which is aligned with the bending axis 332B (i.e., the bending axis 332B progresses through the average angular position 339 of the actuating elements 330A, 330B). Thus, while the actuating elements 330A, 330B may follow a twisting path having an angular extent of 180° over the length of the wrist 320, similar to the exemplary embodiment of FIGS. 10A, 10B, and 11, the twisting does not occur over the length of one joint (e.g., joint 1200A), but all of the twisting occurs over the length of the other joint (e.g., joint 1200B). Additionally, the actuating elements 330A, 330B may be twisted in this manner to cause each of the actuating elements 330A, 330B to be length-maintaining across each joint 1200A and 1200B.

[0104] The wrist may be configured to include any number of joints with different bending axis directions for each joint. Some non-limiting embodiments contemplated within the scope of this disclosure include a wrist having one or more of the wrists 310 and / or 320 of the exemplary embodiments of Figs. 10A-13, where the length of the actuating elements is substantially maintained over the entire length of the wrist. For example, the wrist may include two consecutive wrist devices, each configured according to any of the exemplary embodiments of Figs. 10A-13. Such a wrist may include, for example, a first A-joint, a first B-joint, a second A-joint, and a second B-joint, in order (i.e., the wrist is an ABAB-type wrist). To achieve the length maintenance of the actuating elements over the length of the wrist, the actuating elements may extend along a twist path having an angular extent of 360° over the length of the wrist with twice the angular extent of each of the wrists 310, 320 of the exemplary embodiments of Figs. 10A-13. Conversely, a list containing two consecutive list devices (e.g., an ABAB list) may be simplified to a list containing a single list (e.g., an AB list) such as lists 310 and / or 320 in the exemplary embodiments of Figures 10A-13. Similarly, an AABB list may be simplified to an AB list.

[0105] Various exemplary embodiments according to the present disclosure contemplate torsion configurations for the wrist and actuation elements with various bending axis patterns. The wrist configurations may include only joints with two bending axes, as shown in Figures 8 and 10A-13, although other wrist configurations may be used, such as the ABBA wrist of the exemplary embodiment of Figure 9.

[0106] 14A-14D, cross-sectional views of a wrist joint including four joints 1400A1, 1400B1, 1400B2, and 1400A2 are shown according to an exemplary embodiment. For example, the wrist may be configured according to the exemplary embodiment of the ABBA wrist of FIG 9, and the cross-sectional views of the joints A1, B1, B2, and A2 in FIG 14A-14D may be taken along lines A1-A1, B1-B1, B2-B2, and A2-A2, respectively, in FIG 9. Thus, joints 1400A1, 1400B1, 1400B2, and 1400A2 in Figures 14A-14D respectively represent four different joints of wrist 340 as shown generally in the exemplary embodiment of Figure 15, with joint 1400A1 having bending axis 344 and length 364 (shown generally in Figure 15), joint 1400B1 including bending axis 346 and length 365 (shown generally in Figure 15), joint 1400B2 having bending axis 352 and length 366 (shown generally in Figure 15), and joint 1400A2 having bending axis 354 and length 367 (shown generally in Figure 15). Additionally, wrist 340 has a longitudinal neutral axis 348 as shown in Figures 14A-14D and 15. Axis 348 may be a centerline for wrist 340 and may also be a centerline for the torsional path of actuating elements 342, 350. Actuating elements 342, 350 may be used, for example, to actuate an end effector or to actuate other components of the instrument, such as, for example, a wrist. According to an exemplary embodiment, actuating elements 342, 350 may follow a torsional path such that actuation of actuating elements 342, 350 does not result in reverse motion (e.g., joints 300 and 306 in FIG. 9 do not bend in different directions about axes 290 and 296, and joints 302 and 304 do not bend in different directions about axes 292 and 294), for example, when actuating elements 342, 350 are used to actuate a wrist. According to an exemplary embodiment, the torsion of the actuating elements 342, 350 for each of the joints 1400A1, 1400B1, 1400B2, 1400A2 may be centered about the respective bending axis 344, 346, 352, 354, with the torsion path extending in substantially equal amounts about both sides of the respective bending axis 344, 346, 352, 354.

[0107] The angular extent of the twist of the actuating elements 342, 350 extending across the wrist 340 is such that the actuating elements 342, 350 are length-constant across the length of the wrist 340. At the joint 1400A1, both actuating elements 342, 350 are aligned with the bending axis 344 (i.e., the bending axis 344 runs through the actuating elements 342, 350) and thus have an average angular position 356 across the length 364 of the joint 1400A1 that is aligned with the bending axis 344. Thus, both actuating elements 342, 350 do not change length substantially at the joint 1400A1 and are not twisted at that joint. At the joint 1400B1, the actuating element 342 has an initial position 341 as it enters the joint 1400A1 having an angle 349 of approximately 90° with respect to the bending axis 346. The actuation element 350 also has an initial position 351 when it enters from joint A1 at an angle of approximately 90° to the bending axis 346 .

[0108] In the exemplary embodiment of FIG. 14B, the actuating elements 342, 350 may be twisted 90° at the joint 1400B1 (i.e., may follow a twist path having an angular extent of 90° about the centerline 348) to their respective subsequent positions 343, 353, providing the actuating elements 342, 350 with an average angular position 358 over the length 365 of the joint 1400B1. As shown in the exemplary embodiment of FIG. 14B, the average angular position 358 is not aligned with the bending axis 346, resulting in a positive or negative length change for the actuating elements 342, 350 at the joint 1400B1. As shown in FIG. 14C, at the joint 1400B2, the actuating element 342 has an initial position 345 after entering the joint 1400B1 at an angle 359 of 90° relative to the bending axis 352, and the actuating element 350 has an initial position 355 at 90° relative to the bending axis 352. The actuating elements 342, 350 are twisted 90° at joint 1400B2 (i.e., follow a twist path having an angular extent of 90° about centerline 348) to provide an average angular position 360 over the length 366 of joint 1400B2, resulting in a positive or negative length change for each of the actuating elements 342, 350 at joint 1400B2.

[0109] However, as shown by the average angular positions 358, 360 over the lengths 365, 366 of the joints 1400B1, 1400B2, the twists of the actuating elements 342, 350 at the joints 1400B1, 1400B2 are on either side of the bending axis 346, 352, and the changes in length of the actuating elements 342, 350 substantially cancel each other out. Furthermore, as shown by the average angular position 362 of the actuating elements 342, 350 over the length 367 of the joint 1400A2, the actuating elements 342, 350 are aligned with the bending axis 354 at the joint 1400A2 (i.e., the bending axis 354 passes through the actuating elements 342, 350). As a result, the actuating elements 342, 350 are twisted 180° throughout the length of the wrist 340 (i.e., the twist path has an angular extent of 180° about the centerline 348 (i.e., 90° through each joint 1400B1 and 1400B2). Furthermore, because the twisting of the actuating elements 342, 350 relative to the bending axes 346, 352 of the joints 1400B1 and 1400B2 is on either side of the bending axes 346, 352, the actuating elements 342, 350 do not undergo substantial length changes at the joints 1400A1, 1400A2, and any positive or negative length change of the actuating elements 342, 350 is offset by a corresponding negative or positive length change of the actuating elements 342, 350 at the joint 1400B2, and vice versa. Thus, each actuating element 342 , 350 is length-maintaining along the entire length of the wrist 340 .

[0110] This disclosure contemplates other configurations for wrists having more than two joints. With reference to Figures 16A-16D, cross-sectional views of wrist joints 1600A1, 1600B1, 1600B2, and 1600A2 are shown. Wrist 370 may be configured, for example, according to the exemplary embodiment shown in Figure 9, and the cross-sectional views of joints 1600A1, 1600B1, 1600B2, and 1600A2 in Figures 16A-16D may be taken along lines A1-A1, B1-B1, B2-B2, and A2-A2 for the exemplary embodiment of the ABBA wrist of Figure 9.

[0111] According to an exemplary embodiment, joint 1600A1 has a bending axis 391 and a length 400 (shown generally in the exemplary embodiment of FIG. 17, which shows wrist 370 in its entirety and includes the joints depicted in FIGS. 16A-16D), joint 1600B1 has a bending axis 392 and a length 402 (shown generally in FIG. 17), joint 1600B2 has a bending axis 392 and a length 404 (shown generally in FIG. 17), and joint 1600A2 has a bending axis 394 and a length 406 (shown generally in FIG. 17). Additionally, wrist 370 may include a longitudinal neutral axis 390 that extends through joints 1600A1, 1600B1, 1600B2, and 1600A2, as shown in FIGS. 16A-16D and 17. Axis 390 may be a centerline for wrist 370 and may be a centerline for the torsional path of actuating elements 372, 380. Actuating elements 372, 380 may be used, for example, to actuate an end effector or may actuate other components of the instrument, such as, for example, a wrist. According to an exemplary embodiment, actuating elements 372, 380 may follow a torsional path such that actuation of actuating elements 372, 380 does not result in reverse motion (e.g., joints 300 and 306 in FIG. 9 do not extend in different directions about axes 290 and 296, and joints 302 and 304 do not extend in different directions about axes 292 and 294), for example, when actuating elements 372, 380 are used to actuate a wrist.

[0112] 16A-16D and 17, the actuating elements 372, 380 are initially offset and misaligned from the bending axis 391 at the joint 1600A1. For example, the actuating elements 372, 380 may initially be at an angle 395 of about 30° relative to the bending axis 391. To address this, the actuating elements 372, 380 may be twisted 60° along the length 400 of the joint 1600A1 from their respective initial positions 371, 381 to the subsequent positions 373, 383 (i.e., may follow a twist path having an angular extent of 60° about the centerline 390) such that the actuating elements 372, 380 are length-maintaining at the joint 1600A1. Thus, the average angular position 396 of the actuating elements 372, 380 over the length 400 of the joint 1600A1 is aligned with the bending axis 391 (the bending axis 391 runs through the average angular position 396 of the actuating elements 372, 380).

[0113] Similarly, the actuating elements 372, 380 may be twisted 60° at joint 1600B1 from their respective initial positions 374 to their respective subsequent positions 375, 385 (i.e., may follow a twist path having an angular extent of 60° about centerline 390), and may be twisted 60° at joint 1600B2 from their respective initial positions 376, 386 to their respective subsequent positions 377, 387 (i.e., may follow a twist path having an angular extent of 60° about centerline 390). and may be twisted 60° at joint 1600A2 (i.e., may follow a twisting path having an angular extent of 60° about centerline 390) from their respective initial positions 378, 388 to their subsequent positions 379, 389. Similar to joint A1, the average angular position 399 of the actuating elements 372, 380 over the length 406 of joint 1600A2 may be aligned along bending axis 396 such that the actuating elements 372, 380 are substantially length-constant across joint 1600A2. 94. The actuating elements 372, 380 are not length-constant across the lengths 402, 404 of the respective joints 1600B1, 1600B2. However, when taken generally across the combined lengths 402, 404 of the joints 1600B1 and 1600B2, the actuating elements 372, 380 are substantially length-constant across the combined joints 1600B1 and 1600B2. This is because the actuating elements 372, 380 are substantially length-constant across the combined joints 1600B1 and 1600B2 when viewed generally across the combined lengths 402, 404 of the joints 1600B1 and 1600B2. This is shown by the average angular position 397 of the actuating elements 372, 380 across the length 402 of joint 1600B1 and the average angular position 398 of the actuating elements 372, 380 across the length 404 of joint 1600B2, on either side. Thus, the actuating elements 372, 380 may be twisted a total amount of 240° across the entire length of the wrist 370 (i.e., 60° across each of the lengths of joints 1600A1, 1600B1, 1600B2, 1600A2).

[0114] To extend an actuating element along a torsional path as described in the exemplary embodiments above, various exemplary embodiments contemplate one or more structures that guide the one or more actuating elements along the torsional path. The one or more structures may provide support to the actuating element along its length as it extends along a torsional path according to exemplary embodiments described herein, such as the exemplary embodiments of FIGS.

[0115] 18, a distal portion of a surgical instrument is shown including an actuating element support 410 disposed at a distal end of an instrument shaft, such as shaft 251 of the exemplary embodiment of FIG. 8. According to an exemplary embodiment, a first portion 411 of the actuating element support 410 may include torsional passages 415, 416 that provide a torsional path for actuating elements 426, 428 that extend through passages 415, 416 of the first portion 411. The actuating elements 426, 428 may extend from a proximal end 423 of the actuating element support 410 into a second portion 413 of the actuating element support 410, which includes substantially straight passages 438, 439 through which the actuating elements 426, 428 may extend, as shown in the exemplary embodiment of FIG. 18 for ease of illustration, the second passageway 413 of the actuation element support 410 may include as many passageways as the first portion 411. According to an exemplary embodiment, the passageways of the second portion 413 may be joined to the passageways of the first portion 411 such that any actuation element extending through a passageway of the second portion 413 extends through a corresponding passageway in the first portion 411.

[0116] According to an exemplary embodiment, the support 410 may further include a central passage 419 through which the actuating element 414 may extend. The central passage 419 may extend along a longitudinal centerline 421 of the instrument such that the actuating element 414 or any members extending through the central passage 419, such as a flux conduit, do not undergo a substantial change in length when the support 410 bends. The centerline 421 may be the centerline of the support 410 according to an exemplary embodiment. For example, the actuating element 414 may be used to actuate an end effector, such as a cutting blade. The actuating elements of the various exemplary embodiments described herein that are radially offset from a neutral axis or centerline are not limited to actuating an end effector or wrist, but may be used to actuate other instrument components. For example, an actuation element of various exemplary embodiments described herein that is radially offset from a neutral axis or centerline may actuate a second wrist distal to the actuation element support 410 or other instrument component. In other embodiments, actuation element 414 may be used to actuate an end effector, while actuation elements 426, 428 are used to actuate the wrist to which the end effector is connected. According to other embodiments, a magnetic flux conduit may extend through central passage 419 instead of actuation element 414.

[0117] One or more actuation elements may extend from the actuation element support 410 and connect to devices used to actuate the instrument components. As shown in the exemplary embodiment of FIG. 19, the actuation element support 440 may include a central lumen 442, such as for a flux conduit or actuation element 414 (which may further extend through lumen 424 of connector 420), a lumen 446 for actuation elements 426, 428, and two additional lumens 444 that may be used for other actuation elements or flux conduits. According to an exemplary embodiment, the actuation elements 426, 428 and connector 420 may form a push / pull actuation element that actuates the end effector, for example, when the actuation elements 426, 428 and connector 420 are pushed or pulled along direction 435. Referring to FIG. 20, a side view of the end effector 434 is shown in a closed configuration, with the protrusion 422 of the connector 420 extending through a slot 437 of the end effector 404. When actuation elements 426, 428, connector 420, and protrusion 422 are pushed in direction 425, protrusion 422 moves through slot 437, forcing end effector 434 into the open configuration as shown in FIGS.

[0118] Although the actuation elements 426, 428 may be used as push / pull actuation elements, the actuation elements 426, 428 may alternatively be used as pull / pull actuation elements. For example, the actuation elements 426, 428 may be attached to the proximal end 409 of the end effector 404 without the connector 420 such that the end effector 404 may be opened by pulling one of the actuation elements 426, 428 and closed by pulling the other of the actuation elements 426, 428.

[0119] According to an exemplary embodiment, the wrist can bend, which can change the length of the actuating elements extending through the wrist, so that the actuating element support can be positioned within the surgical instrument such that the location of the actuating element support corresponds to the location of the wrist. The central passageway 419 is disposed along the longitudinal centerline 421 of the instrument, so that the actuating elements 426, 428 and their respective passageways 415, 416 are radially offset from the centerline 421. Thus, when the wrist 430 is actuated to bend the instrument to position the end effector 434 at a desired location, the actuating elements 426, 428 may undergo a change in length. However, according to the exemplary embodiment of FIGS. 10A-17, the actuating element support 440 provides a torsional path for the actuating elements 426, 428, so that the actuating elements 426, 428 do not undergo a substantial change in length over the length of the wrist 430.

[0120] The passages 415, 416 are twisted 180° in the exemplary embodiment of FIG. 18, although other configurations of twist may be used, as described in the exemplary embodiment of FIGS. 10A-17. The actuating element support 410 may include various numbers of passages to provide a twist path for one or more actuating elements. For example, the actuating element support 410 may include one passage, two passages, three passages, or four or more passages. For example, the actuating element support 410 may include a third passage 417 and a fourth passage 418 that may be used for additional actuating elements, such as electrical conductors that provide electrical energy to an end effector (not shown), or for magnetic flux conduits 427, 429.

[0121] As shown in the exemplary embodiment of FIG. 18, the actuation element support 410 may have a solid, unitary molded structure with passages 415-418 formed through the length of the actuation element support 410. According to an exemplary embodiment, the actuation element support 410 may be manufactured, for example, by extruding a polymer material into a substantially cylindrical shape, with the torsional passages 415-418 formed through the length of the polymer material. However, other manufacturing methods may be utilized to provide the support 410 with one or more torsional passages that are radially offset from a centerline 421 of the support 410 and twisted about the centerline 421 of the support 410. Thus, the support 410 may guide one or more actuation elements along a torsional path and provide support to the actuation elements to minimize or eliminate buckling of the actuation elements. For example, when the actuation elements are used as push / pull actuation elements and the actuation elements are pushed, the support 410 may reduce or eliminate buckling of the actuation elements.

[0122] In various exemplary embodiments, the support 410 may be flexible to facilitate bending of the support 410 when a wrist through which the support 410 extends is actuated. The support 410 may be made of, for example, a polymeric material that provides a relatively low coefficient of friction. According to exemplary embodiments, the support 410 may be made of, for example, polyether block amide (PEBAX), fluorinated ethylene propylene (PEP), and other polymeric materials having a relatively low coefficient of friction that are well known to those of skill in the art. Additionally, the actuating elements extending through the support 410 may be coated with a material that minimizes friction between the actuating elements and the support 410. For example, the actuating elements may be coated with polytetrafluoroethylene (PTFE) or other lubricious materials that are well known to those of skill in the art.

[0123] As shown in the exemplary embodiment of FIG. 19, the working element support 440 includes five lumens 442, 444, 446. However, a surgical instrument including a working element support is not limited to only five lumens, and a greater or lesser number of lumens may be used in the instrument. For example, the working element support 450 may include seven lumens 452, as shown in the exemplary embodiment of FIG. 22. In addition, the lumens of the working element support need not be arranged as a single ring of lumens around a central lumen, as in the exemplary embodiment of FIG. 22. Instead, the lumens 462 of the support 460 may be arranged in multiple concentric rings around a central lumen, as shown in the exemplary embodiment of FIG. 23.

[0124] As discussed above with respect to the exemplary embodiment of FIG. 18, the actuation element support may have a one-piece structure. For example, the support may be an extruded one-piece piece. Such an extrusion may have a solid, substantially continuous outer surface without grooves. However, other configurations and structures for the actuation element support may be used. For example, the actuation element support may include one or more material weakened areas that enhance the flexibility of the support. Referring to FIG. 24, an exemplary embodiment of an actuation element support 710 is shown, with actuation elements 724, 726 extending through the support 710. To enhance the flexibility of the support 710, such as when the support 710 is bent by the wrist, the support 710 may include one or more material weakened areas, such as grooves 712, as shown in the exemplary embodiment of FIG. 24. According to an exemplary embodiment, the support 710 may be formed as an extrusion with lumens formed through the support 710, similar to the exemplary embodiment of FIG. 19, and may have grooves 712 cut into the extrusion resulting in vertebrae 714 separated by the grooves 712. As shown in FIG. 25, a cross-sectional view taken along line 25-25 of FIG. 24, the support 710 may include five lumens 711, 713, 715, 717, 719, similar to the exemplary embodiment of FIG. 19. However, the support 710 may include other numbers of lumens and may include the lumen configurations of the exemplary embodiments of FIGS. 22 and 23. According to an exemplary embodiment, the support 710 may include other weakened areas in addition to the grooves. For example, the support 710 may include holes 730, which may be formed in the vertebrae 714 to provide additional weakened areas for the support 710 to provide enhanced flexibility.

[0125] According to an exemplary embodiment, the actuation element may be supported by components other than the integrally molded structure of Figures 18, 24 and 25 and may be shaped into a torsional path. Referring to Figure 26, an exploded view of an actuation support 800 formed by a plurality of separate links 802-805 is shown according to an exemplary embodiment. The links 802-805 may include one or more passages 810, 812 for an actuation element (not shown). As shown in the exemplary embodiment of Figure 26, the links 802-805 may be rotated about a longitudinal axis 816 (i.e., centerline) of the support 800 in a direction 818 to impart a twist to the actuation element traveling through the passages 810, 812. Thus, the passages 810, 812 of the links 802-805 may have different angular positions relative to the centerline 816 for each link. Links 802-805 may impart other amounts of twist, such as the amounts of twist discussed in the exemplary embodiment of Figures 10A-17. Additionally, links 802-805 may include other numbers of lumens and may include the lumen configurations of the exemplary embodiment of Figures 22 and 23.

[0126] As shown in the exemplary embodiment of FIG. 18, the lumens 415-418 of the actuating element support 410 may twist in one direction from one end of the support 410 to the other. However, the actuating element support is not limited to such a twisted configuration and may instead include lumens that twist in more than one direction. With reference to FIG. 27, an exemplary embodiment of an actuating element support 470 is shown that includes lumens 472, 474 that twist in a first direction 476 along the support 470 in direction 471 and then reverse to twist along direction 478. Furthermore, the amount of twisting may be constant along the length of the support or may vary by increasing or decreasing along the length of the support.

[0127] As discussed above, the actuation element support may function to guide the actuation element along the torsional path as well as to support the actuation element to minimize or prevent buckling of the actuation element. Other structures may be provided that may be used in conjunction with the actuation element support to enhance the support of the actuation element and its buckling strength. Referring to FIG. 28, an exemplary embodiment of an actuation element 500 is shown that includes a rigid section 510 at the distal end of the non-supporting section 502 of the actuation element 500. As shown in FIG. 29, which is an enlarged view of a portion 504 of FIG. 28, the actuation element 500 may include a wire or cable 506 that extends to the rigid section 510. The wire or cable 506 may be, for example, one of the actuation elements 426, 428 of the exemplary embodiment of FIG. 18. The rigid section 510 may include a rigid cylinder 512 that fits over the wire or cable 506. The rigid cylinder 512 may be made of steel, such as, for example, stainless steel. The rigid cylinder 512 may be connected to the wire or cable 506, for example, via crimping the cylinder 512 to the wire or cable 506.

[0128] According to an exemplary embodiment, the unsupported section 502 of the wire or cable 506 may include a coating 508. The coating may be used, for example, to provide the wire or cable 506 with a smooth surface having a lower coefficient of friction than the wire or cable 506. The coating 508 may be made of a polymer, such as a thermoplastic. According to an exemplary embodiment, the coating 508 may be made of, for example, PTFE, ethylene tetrafluoroethylene (ETFE), silicone, or other coating materials well known to those skilled in the art. According to an exemplary embodiment, the coating 508 may have a thickness that is substantially the same as the thickness of the cylinder 512, as shown in FIG. 29.

[0129] By providing the actuating element 500 with the rigid section 510, the buckling strength of the actuating element 500 may be enhanced. For example, when the actuating element 500 is inserted through the actuating element support 530 (e.g., the actuating element support 410 in the exemplary embodiment of FIG. 18), the actuating element 500 may be pushed along a direction 534, causing a distal end of the actuating element 500 to extend beyond a distal end 532 of the actuating element support 530, as shown in the exemplary embodiment of FIG. 30. Because the actuating element 500 includes the rigid section 510, the portion of the actuating element 500 that extends beyond the distal end 532 of the actuating element support 530 may have enhanced buckling strength. For example, a surgical instrument may be configured such that when the actuating element 500 is pushed in the direction 534, the unsupported portion of the actuating element 500 remains within the actuating element support 530, and only the rigid section 510 of the actuating element 500 extends beyond the distal end of the actuating element 530, as shown in FIG. 30.

[0130] According to an exemplary embodiment, the proximal end of the actuating element 500 may also include a rigid section 520, as shown in FIG. 28, although other exemplary embodiments may lack a rigid section at the proximal end of the actuating element. The rigid section 520 at the proximal end may be configured according to the rigid section 510 of the exemplary embodiment of FIG. 29. According to an exemplary embodiment, the rigid section 520 may extend beyond the proximal end of the actuating element support when the actuating element is pushed, for example, similar to the exemplary embodiment of FIG. 30.

[0131] Another structure that may be used to support the actuation element is a flexible shaft. Referring to FIG. 31, an exemplary embodiment of a flexible shaft 600 is shown, which includes a compression member 610 and a tension member 614. The flexible shaft 600 may be used to support the actuation element, and the flexible shaft 600 extends through at least a portion of the actuation element support, similar to the exemplary embodiment of FIG. 30. The compression member 610 may have a central lumen 612 for the actuation element to travel through. The compression member 610 may be, for example, a spring including windings that compress against each other when a compressive force is applied along a longitudinal axis 616 of the flexible shaft 600. The tension member 614 may be a wire or cable attached to the compression member 610 such that it is external to the compression member 610 to resist a tensile force applied along the axis 616 or a bending force applied to the flexible shaft 600. In other words, the flexible shaft 600 may be a combination of a compression member 610 that resists compression that would compress the tension member 614 if the compression member 610 was not present, and a tension member 614 that resists tension and bending that would otherwise pull the compression member 610 apart.

[0132] According to an exemplary embodiment, the actuation element support may include multiple flexible shaft layers. For example, the actuation element support may include multiple flexible shafts layered on top of each other, such as by providing multiple layers of flexible shafts 600 of the exemplary embodiment of FIG. 31 that overlap each other. The various layers of flexible shafts may be coaxial with each other. For example, as shown in the exemplary embodiment of FIG. 32, the actuation element support 1000 may include a first flexible tube 1002 and a second flexible tube 1004 that are coaxial with each other, with one or more actuation elements 1010 extending through the support 1000. Although only two coaxial tubes 1002, 1004 are depicted in the exemplary embodiment of FIG. 36, the support 1000 may include other numbers of coaxial tubes, such as, for example, three, four, or more flexible coaxial tubes. The flexible tubes 1002, 1004 may be flexible due to removal of material from the tubes 1002, 1004, for example, via cutting grooves or slits in the tubes 1002, 1004 to provide weakened areas that allow the tubes 1002, 1004 to flex, according to an exemplary embodiment. According to an exemplary embodiment, the tubes 1002, 1004 may be solid helical springs, useful for compressive loads, with wound filaments, useful for tensile loads.

[0133] According to other exemplary embodiments, the flexible shaft supporting the actuation member may include multiple layers of wound filaments connected to each other. For example, instead of including the compression member 610 of the exemplary embodiment of FIG. 31, the flexible shaft may include multiple tension members 614 connected to each other, such as by braiding the tension members 614 together. According to exemplary embodiments, the actuation element support may be a flexible shaft formed by a tube with portions removed, such as, for example, via cutting the tube in one or more places to enhance the flexibility of the tube. The tube may be made of, for example, stainless steel, thermoplastic, or other materials familiar to those skilled in the art.

[0134] The exemplary embodiments and methods described herein are described as being utilized with surgical instruments for a teleoperated surgical system. However, the exemplary embodiments and methods described herein may be utilized with other surgical devices, such as laparoscopic instruments and other handheld instruments. Additionally, the exemplary embodiments and methods may be utilized in other applications that utilize a remotely actuable wrist or multiple articulated structures, such as for remotely positioning an object attached to the wrist or articulated structure.

[0135] By providing a surgical instrument with an actuating element configured to substantially maintain its length when the surgical instrument is bent, the actuating element may be enabled to actuate components of the instrument without substantial interference from changes in its length, and the surgical instrument may have a simplified design that is relatively easy to manufacture.

[0136] Further modifications and alternative embodiments will be apparent to those skilled in the art in view of the disclosure herein. For example, the systems and methods may include additional components or steps omitted from the drawings and description for clarity of operation. This description should therefore be interpreted as merely illustrative and is for the purpose of teaching those skilled in the art the general manner of carrying out the present teachings. It should be understood that the various embodiments shown and described herein are to be taken as illustrative. Elements and materials, and the arrangements of those elements and materials, may be substituted for those illustrated and described herein, parts and processes may be reversed, and specific configurations of the present teachings may be utilized independently, all as would be apparent to those skilled in the art after having the benefit of the description herein. Changes may be made in the elements described herein without departing from the spirit and scope of the present teachings and the following claims.

[0137] It should be understood that the particular examples and embodiments shown herein are non-limiting, and that changes in structure, dimensions, materials, and methodology may be made without departing from the scope of the present teachings.

[0138] Other embodiments in accordance with this disclosure will be apparent to those skilled in the art from consideration of the specification and practice of the invention disclosed herein. It is intended that the specification and examples be considered as exemplary only, with a true scope and spirit being indicated by the following claims.

Claims

1. an articulatable wrist including a longitudinal centerline, a first joint, and a second joint; an end effector coupled to the articulatable wrist; a flexible actuation element operatively coupled to the end effector and routed through the articulatable wrist; the actuation element follows a torsional path along at least a portion of the articulatable wrist; the actuating element is positioned within the torsional path such that a positive or negative longitudinal change in a portion of the actuating element within a portion of the torsional path due to bending of the articulatable wrist by the first joint and the second joint is substantially offset by another portion of the actuating element within another portion of the torsional path; the actuating element is positioned within the torsional path such that positive or negative longitudinal changes in a portion of the actuating element within a portion of the torsional path due to bending of the articulatable wrist by one of the first joint or the second joint are not substantially cancelled in the portion of the torsional path; the twisting path extends in a first angular extent along an arc from an initial position to a subsequent position relative to the longitudinal centerline of the wrist at a predetermined distance from the longitudinal centerline along the first joint; the twisting path extends in a second angular extent along an arc from an initial position to a subsequent position relative to the longitudinal centerline at the predetermined distance from the longitudinal centerline of the wrist along the second joint. Surgical instruments.

2. The surgical instrument further includes a shaft and a transmission mechanism coupled to the manipulator and configured to receive a driving force from the manipulator; the shaft extends proximally from the articulatable wrist and includes a proximal end portion; the transmission mechanism is at the proximal end portion of the shaft; the transmission mechanism is configured to transmit the driving force to the end effector through the actuating element extending from the transmission mechanism; 10. The surgical instrument of claim 1.

3. The surgical instrument of claim 2 , wherein the transmission mechanism is configured to transmit the drive force along the actuating element to actuate the end effector.

4. The surgical instrument of claim 2 , wherein the transmission mechanism is configured to transmit the drive force along the actuation element to actuate the wrist.

5. a longitudinal centerline is defined for said articulatable wrist; the twisting path is radially offset from and twists about the longitudinal centerline of the articulatable wrist. A surgical instrument according to any one of claims 1 to 4.

6. the first joint having a first bending axis about which the wrist is articulatable; the second joint having a second bending axis about which the wrist is articulatable; The first bending axis and the second bending axis are perpendicular to each other. A surgical instrument according to any one of claims 1 to 5.

7. the list further includes a third joint; the actuation element is configured to substantially counteract positive or negative longitudinal changes due to bending of the articulatable wrist by the third joint. A surgical instrument according to any one of claims 1 to 6.

8. A surgical instrument according to any preceding claim, wherein the torsional path generally through the first joint and the second joint has an angular extent of 180 degrees along an arc.

9. The surgical instrument of any one of claims 1 to 6, wherein the torsional path generally through the first joint and the second joint has an angular extent along an arc of 240 degrees.

10. The surgical instrument of claim 1 , wherein the first angular extent and the second angular extent have different magnitudes from one another.

11. the first angular extent and the second angular extent are equal in magnitude to one another; the twist path through the first angular extent and the twist path through the second angular extent are positioned opposite one another relative to the longitudinal centerline.

10. The surgical instrument of claim 1.

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