Handheld adjustable articulating needle driver

Abstract

A needle driver device including a first jaw and a second jaw. The device further includes handle members operatively coupled to the jaws. Each handle member includes ratcheting joints configured to bend to a desired angle and lock into place. Each ratcheting joint includes a bend configured to freely bend in within a range of angles, an arm coupled to the handle member adjacent to the bend, and a plurality of grooves disposed along the handle member. Each hook of the arm may be configured to interlock with a groove to bend the bend and lock the bend in place.

Description

Reference No.: BCM 24.03 PCT Inventor’s last name: Kirby, et al. Document Date: August 13, 2025HANDHELD ADJUSTABLE ARTICULATING NEEDLE DRIVERCROSS-REFERENCE TO RELATED APPLICATIONS

[0001] This application claims benefit of U.S. Provisional Application No. 63 / 684,203 filed August 16, 2024, the specification of which is incorporated herein in its entirety by reference.FIELD OF THE INVENTION

[0002] The present invention is directed to articulating needle driver devices for use by surgeons to maximize efficiency and hand stability during surgical procedures.BACKGROUND OF THE INVENTION

[0003] In some valve surgeries, and other operations that require difficult angles of approach, the surgeon is sometimes forced to remain in ergonomically unfavorable positions for extended periods of time, leading to fatigue and soreness (i.e. flared and elevated elbows). Positions like this forgo the stabilizing effect of steadying the surgeon's hand on the operating field. A potential solution would be to have a needle driver that is able to bend in unique ways to provide steadier, and more ergonomically favorable, access to more difficult angles of approach.

[0004] Prior systems implement wrenches with adjustable jaws in order to accommodate components of differing diameters. However, these prior systems do not allow for ratcheting adjustment of the handle component(s), and the adjustments that are implemented in the jaw do not allow the angle to be changed. Other prior systems implement robotic systems with bending joints that allow for a needle to be rotated to a plurality of different angles. However, these prior systems are limited in the range of angles at which the needle can be rotated and oriented. Other prior systems implement needle driver devices with rotational driving arms for driving a needle. However, these prior systems do not allow for the needle’s angle of entry to be adjusted and locked in place. Thus, there exists a present need for a needle driver device that is able to articulate and bend to provide better ergonomics than currently available needle drivers.BRIEF SUMMARY OF THE INVENTION

[0005] It is an objective of the present invention to provide devices that allow for articulating needle driver devices for use by surgeons to maximize efficiency and handReference No.: BCM 24.03 PCT Inventor’s last name: Kirby, et al. Document Date: August 13, 2025 stability during surgical procedures, as specified in the independent claims. Embodiments of the invention are given in the dependent claims. Embodiments of the present invention can be freely combined with each other if they are not mutually exclusive.

[0006] The present invention features a needle driver device. The device may comprise a first jaw and a second jaw. The device may further comprise one or more handle members operatively coupled to the first jaw and the second jaw. Each handle member may comprise one or more ratcheting joints configured to bend to a desired angle of a plurality of angles and lock into place at the desired angle. Each ratcheting joint may comprise a bend configured to freely bend in within a range of angles. Each ratcheting joint of each handle member may further comprise an arm coupled to the handle member adjacent to the bend, comprising one or more hooks. Each ratcheting joint of each handle member may further comprise a plurality of grooves disposed along the handle member. Each hook of the one or more hooks may be configured to interlock with a groove to bend the bend and lock the bend in place.

[0007] 0ne of the unique and inventive technical features of the present invention is the implementation of ratcheting joints on a handle component of a scissor-like needle driver. Without wishing to limit the invention to any theory or mechanism, it is believed that the technical feature of the present invention advantageously provides for manual adjustment and configurability of a needle driver device. None of the presently known prior references or works have the unique inventive technical feature of the present invention.

[0008] Furthermore, the inventive technical feature of the present invention contributed to a surprising result. One of ordinary skill in the art would expect that the use of manual locking joints would be inefficient when compared to the use of motorized systems with rotary joints. The present invention implements a novel ratcheting joint design in a handheld scissor-like needle driver device. Surprisingly, this ratcheting joint design allows for the present invention to achieve a cost- and material-efficient handheld device design with a wide range of angles to which the handles can be configured. Thus, the inventive technical feature of the present invention contributed to a surprising result.

[0009] Any feature or combination of features described herein are included within theReference No.: BCM 24.03 PCT Inventor’s last name: Kirby, et al. Document Date: August 13, 2025 scope of the present invention provided that the features included in any such combination are not mutually inconsistent as will be apparent from the context, this specification, and the knowledge of one of ordinary skill in the art. Additional advantages and aspects of the present invention are apparent in the following detailed description and claims.BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)

[0010] The features and advantages of the present invention will become apparent from a consideration of the following detailed description presented in connection with the accompanying drawings in which:

[0011] FIG. 1 shows a view of the needle driver device of the present invention.

[0012] FIG. 2A shows a side view of the ratcheting joints of the present invention with rectangular-shaped bends.

[0013] FIG. 2B shows a side view of the ratcheting joints of the present invention with triangular-shaped bends.

[0014] FIG. 3A shows a close-up view of a ratcheting joint of the present invention showing a 15-degree range of bending.

[0015] FIG. 3B shows a close-up view of a ratcheting joint of the present invention while bending.

[0016] FIG. 4 shows a photograph of a prototype of the needle driver device of the present invention.

[0017] FIGs 5A-5D show photographs of a handle member of the needle driver device of the present invention at various degrees of bending.

[0018] FIG. 6 shows a flowchart of a method for adjusting and locking an angle of an adjustable needle driver device of the present invention.DETAILED DESCRIPTION OF THE INVENTION

[0019] Following is a list of elements corresponding to a particular element referred to herein:

[0020] 100 device

[0021] 110 first jaw

[0022] 115 second jaw

[0023] 120 handle membersReference No.: BCM 24.03 PCT Inventor’s last name: Kirby, et al. Document Date: August 13, 2025

[0024] 122 first handle member

[0025] 124 second handle member

[0026] 125 pivot

[0027] 130 ratcheting joints

[0028] 132 bend

[0029] 134 arm

[0030] 136 grooves

[0031] The term “needle driver” is defined herein as a surgical instrument used by doctors and surgeons to hold and push a suturing needle.

[0032] The term “desired angle” is defined herein as an angle determined by the medical professional using the device to be useful for driving a needle in the current procedure.

[0033] Referring now to FIG. 1 , the present invention features a needle driver device (100). In some embodiments, the device (100) may comprise a first jaw (110). The device (100) may further comprise a second jaw (115). The device (100) may further comprise one or more handle members (120) operatively coupled to the first jaw (110) and the second jaw (115). Each handle member may comprise one or more ratcheting joints (130). Each ratcheting joint may be configured to bend to a desired angle of a plurality of angles and lock into place at the desired angle. In some embodiments, each ratcheting joint of each handle member may comprise a bend (132) configured to freely bend in within a range of angles. Each ratcheting joint of each handle member may further comprise an arm (134) having a proximal end and a distal end, coupled to the handle member by the proximal end adjacent to the bend (132), comprising one or more hooks at the distal end. Each ratcheting joint of each handle member may further comprise a plurality of grooves (136) disposed lengthwise along the handle member adjacent to the arm (134). The bend (132) may be located between the plurality of grooves (136) and proximal end of the arm (134). Each hook of the one or more hooks may be configured to interlock with a groove of the plurality of grooves (136). Interlocking the hook with the groove may bend the bend (132) and lock the bend (132) in place such that the first (110) and second (115) jaws are repositioned relative to the one or more handle members (120).

[0034] In some embodiments, the bend (132) may comprise a rectangular shape or aReference No.: BCM 24.03 PCT Inventor’s last name: Kirby, et al. Document Date: August 13, 2025 triangular shape. In some embodiments, the one or more ratcheting joints (130) of each handle member may comprise a plurality of ratcheting joints (130). The plurality of ratcheting joints (130) may comprise a first set of joints configured to bend in a first direction and a second set of joints configured to bend in a second direction. In some embodiments, the second direction may be opposite the first direction. In some embodiments, the needle driver device (100) may comprise a plastic material, a metal material, or a combination thereof. In some embodiments, the needle driver device (100) may be fabricated by a three-dimensional printing process.

[0035] In some embodiments, the one or more handle members (120) may comprise a pair of handle members. The pair of handle members may comprise a first handle member (122) operatively coupled to the first jaw (110) by a pivot (125) such that moving the first handle member (122) moves the first jaw (110) with respect to the second jaw (115) between an open position and a closed position. The pair of handle members may further comprise a second handle member (124) operatively coupled to the second jaw (115) by the pivot (125) such that moving the second handle member (124) moves the second jaw (115) with respect to the first jaw (110) between the open position and the closed position.

[0036] Referring now to FIG. 6, the present invention features a method for adjusting a configuration of a needle driver device (100). In some embodiments, the method may comprise providing the needle driver device (100). The needle driver device (100) may comprise a first jaw (110). The needle driver device (100) may further comprise a second jaw (115). The needle driver device (100) may further comprise one or more handle members (120) operatively coupled to the first jaw (110) and the second jaw (115), each handle member comprising one or more ratcheting joints (130), each ratcheting joint configured to bend to a desired angle of a plurality of angles and lock into place at the desired angle. The method may further comprise bending at least one of the one or more ratcheting joints (130) of the one or more handle members (120) to the desired angle. The method may further comprise locking the at least one of the one or more ratcheting joints (130) of the one or more handle members (120) at the desired angle.

[0037] In some embodiments, each ratcheting joint of each handle member mayReference No.: BCM 24.03 PCT Inventor’s last name: Kirby, et al. Document Date: August 13, 2025 comprise a bend (132) configured to freely bend in within a range of angles. Each ratcheting joint may further comprise an arm (134) having a proximal end and a distal end, coupled to the handle member by the proximal end adjacent to the bend (132), comprising one or more hooks at the distal end. Each ratcheting joint may further comprise a plurality of grooves (136) disposed lengthwise along the handle member adjacent to the arm (134). The bend (132) may be located between the plurality of grooves (136) and proximal end of the arm (134). Each hook of the one or more hooks is configured to interlock with a groove of the plurality of grooves (136). Interlocking the hook with the groove may bend the bend (132) and lock the bend (132) in place such that the first (110) and second (115) jaws are repositioned relative to the one or more handle members (120).

[0038] In some embodiments, bending the at least one of the one or more ratcheting joints (130) of the one or more handle members (120) to the desired angle comprises bending the bend (132) such that the one or more hooks of the arm (134) are aligned with a groove of the plurality of grooves (136) at the desired angle. In some embodiments, locking the at least one of the one or more ratcheting joints (130) of the one or more handle members (120) at the desired angle comprises interlocking the one or more hooks of the arm (134) with the groove of the plurality of grooves (136) such that the bend (132) is locked in place at the desired angle. In some embodiments, the plurality of ratcheting joints (130) may comprise a first set of joints configured to bend in a first direction and a second set of joints configured to bend in a second direction. In some embodiments, the second direction may be opposite the first direction.

[0039] ln some embodiments, the needle driver device (100) of the present invention may comprise a lightweight rigid material. The material may comprise a lightweight plastic material (i.e., polycarbonate, polyethylene, polypropylene, etc.), a lightweight metal material (i.e., stainless steel, copper, aluminum, etc.), or a combination thereof. The material of the needle driver device (100) may be sterilized for use in and / or around exposed internal areas of the body. The material of the needle driver device (100) may be lightweight such that the device (100) can be efficiently used as a handheld device.

[0040] ln some embodiments, the needle driver device (100) of the present invention may be used in a wide array of medical applications. The medical applications mayReference No.: BCM 24.03 PCT Inventor’s last name: Kirby, et al. Document Date: August 13, 2025 comprise wound closure, ligation, eye surgery, microsurgery, dental surgery, or a combination thereof.

[0041] ln some embodiments, the needle driver device (100) of the present invention may be configured as a scissor-like device. As a non-limiting example, the needle driver device (100) may comprise two jaws each attached to a handle component at a pivot point (125) such that the jaws apply pressure against each other when the handles are squeezed together. In some embodiments, the needle driver device (100) of the present invention may comprise two jaws coupled to a single handle comprising an actuation mechanism (i.e., a lever, a button, etc.) such that actuating the actuation mechanism causes the jaws to press together. In some embodiments, the needier driver device (100) of the present invention may comprise a single jaw component attached to a single handle comprising an actuation mechanism (i.e., a lever, a button, etc.) such that actuating the actuation mechanism causes the single jaw to stabilize the needle in place such that the first (110) and second (115) jaws are repositioned relative to the one or more handle members (120).

[0042] ln some embodiments, the needle driver device (100) of the present invention may comprise a plurality of ratcheting joints (130). The ratcheting joints (130) may be incorporated into the jaw components, the handle components, or a combination thereof. The ratcheting joints (130) may be integrated into components of the needle driver device (100) in sets of 1 to 5 joints. Each joint may comprise a bending range of 0 to 179 degrees. Each joint may comprise one or more grooves comprising 1 to 5 grooves, each allowing the bend to be locked at a different angle.

[0043] Although there has been shown and described the preferred embodiment of the present invention, it will be readily apparent to those skilled in the art that modifications may be made thereto which do not exceed the scope of the appended claims. Therefore, the scope of the invention is only to be limited by the following claims. In some embodiments, the figures presented in this patent application are drawn to scale, including the angles, ratios of dimensions, etc. In some embodiments, the figures are representative only and the claims are not limited by the dimensions of the figures. In some embodiments, descriptions of the inventions described herein using the phrase “comprising” includes embodiments that could be described as “consisting essentiallyReference No.: BCM 24.03 PCT Inventor’s last name: Kirby, et al. Document Date: August 13, 2025 of” or “consisting of”, and as such the written description requirement for claiming one or more embodiments of the present invention using the phrase “consisting essentially of” or “consisting of” is met.

[0044] The reference numbers recited in the below claims are solely for ease of examination of this patent application, and are exemplary, and are not intended in any way to limit the scope of the claims to the particular features having the corresponding reference numbers in the drawings.

Claims

Reference No.: BCM 24.03 PCT Inventor’s last name: Kirby, et al. Document Date: August 13, 2025WHAT IS CLAIMED IS:1) A needle driver device (100) comprising: a) a first jaw (110); b) a second jaw (115); and c) one or more handle members (120) operatively coupled to the first jaw (110) and the second jaw (115), each handle member comprising one or more ratcheting joints (130), each ratcheting joint configured to bend to a desired angle of a plurality of angles and lock into place at the desired angle.2) The device (100) of claim 1 , wherein each ratcheting joint of each handle member comprises: a) a bend (132) configured to freely bend in a range of angles; b) an arm (134) having a proximal end and a distal end, coupled to the handle member by the proximal end adjacent to the bend (132), comprising one or more hooks at the distal end; and c) a plurality of grooves (136) disposed lengthwise along the handle member adjacent to the arm (134); wherein the bend (132) is located between the plurality of grooves (136) and proximal end of the arm (134); wherein each hook of the one or more hooks is configured to interlock with a groove of the plurality of grooves (136), wherein interlocking the hook with the groove bends the bend (132) and locks the bend (132) in place such that the first (110) and second (115) jaws are repositioned relative to the one or more handle members (120).3) The device (100) of claim 1 , wherein the bend (132) comprises a rectangular shape or a triangular shape.4) The device (100) of claim 1 , wherein the one or more ratcheting joints (130) of each handle member comprise a plurality of ratcheting joints (130), wherein the plurality of ratcheting joints (130) comprise a first set of joints configured to bend in a first direction and a second set of joints configured to bend in a secondReference No.: BCM 24.03 PCT Inventor’s last name: Kirby, et al. Document Date: August 13, 2025 direction.5) The device (100) of claim 4, wherein the second direction is opposite the first direction.6) The device (100) of claim 1 , wherein the needle driver device (100) comprises a plastic material, a metal material, or a combination thereof.7) The device (100) of claim 1 , wherein the needle driver device (100) is fabricated by a three-dimensional printing process.8) The device (100) of claim 1 , wherein the one or more handle members (120) comprise a pair of handle members comprising: a) a first handle member (122) operatively coupled to the first jaw (110) by a pivot (125) such that moving the first handle member (122) moves the first jaw (110) with respect to the second jaw (115) between an open position and a closed position; and b) a second handle member (124) operatively coupled to the second jaw (115) by the pivot (125) such that moving the second handle member (124) moves the second jaw (115) with respect to the first jaw (110) between the open position and the closed position.9) A needle driver device (100) comprising: a) a first jaw (110); b) a second jaw (115); c) a first handle member (122) operatively coupled to the first jaw (110) by a pivot (125) such that moving the first handle member (122) moves the first jaw (110) with respect to the second jaw (115) between an open position and a closed position; and d) a second handle member (124) operatively coupled to the second jaw (115) by the pivot (125) such that moving the second handle member (124) moves the second jaw (115) with respect to the first jaw (110) between the open position and the closed position; e) a plurality of ratcheting joints (130) disposed on the first handle member (122) and the second handle member (124), each ratcheting joint configured to bend to a desired angle of a plurality of angles and lock into place at the desired angle, wherein each ratcheting joint of each handle member comprises:Reference No.: BCM 24.03 PCT Inventor’s last name: Kirby, et al. Document Date: August 13, 2025 i) a bend (132) configured to freely bend in within a range of angles; ii) an arm (134) having a proximal end and a distal end, coupled to the handle member by the proximal end adjacent to the bend (132), comprising one or more hooks at the distal end; and iii) a plurality of grooves (136) disposed lengthwise along the handle member adjacent to the arm (134); wherein the bend (132) is located between the plurality of grooves (136) and proximal end of the arm (134); wherein each hook of the one or more hooks is configured to interlock with a groove of the plurality of grooves (136), wherein interlocking the hook with the groove bends the bend (132) and locks the bend (132) in place such that the first (110) and second (115) jaws are repositioned relative to the one or more handle members (120).10)The device (100) of claim 9, wherein the bend (132) comprises a rectangular shape or a triangular shape.11 )The device (100) of claim 9, wherein the plurality of ratcheting joints (130) comprise a first set of joints configured to bend in a first direction and a second set of joints configured to bend in a second direction.12)The device (100) of claim 11 , wherein the second direction is opposite the first direction.13)The device (100) of claim 9, wherein the needle driver device (100) comprises a plastic material, a metal material, or a combination thereof.14)The device (100) of claim 9, wherein the needle driver device (100) is fabricated by a three-dimensional printing process.15)A method for adjusting a configuration of a needle driver device (100), the method comprising: a) providing the needle driver device (100) comprising: i) a first jaw (110); ii) a second jaw (115); andReference No.: BCM 24.03 PCT Inventor’s last name: Kirby, et al. Document Date: August 13, 2025 iii) one or more handle members (120) operatively coupled to the first jaw (110) and the second jaw (115), each handle member comprising one or more ratcheting joints (130), each ratcheting joint configured to bend to a desired angle of a plurality of angles and lock into place at the desired angle; b) bending at least one of the one or more ratcheting joints (130) of the one or more handle members (120) to the desired angle; and c) locking the at least one of the one or more ratcheting joints (130) of the one or more handle members (120) at the desired angle.16)The method of claim 15, wherein each ratcheting joint of each handle member comprises: a) a bend (132) configured to freely bend in within a range of angles; b) an arm (134) having a proximal end and a distal end, coupled to the handle member by the proximal end adjacent to the bend (132), comprising one or more hooks at the distal end; and c) a plurality of grooves (136) disposed lengthwise along the handle member adjacent to the arm (134); wherein the bend (132) is located between the plurality of grooves (136) and proximal end of the arm (134); wherein each hook of the one or more hooks is configured to interlock with a groove of the plurality of grooves (136), wherein interlocking the hook with the groove bends the bend (132) and locks the bend (132) in place such that the first (110) and second (115) jaws are repositioned relative to the one or more handle members (120).17)The method of claim 16, wherein bending the at least one of the one or more ratcheting joints (130) of the one or more handle members (120) to the desired angle comprises bending the bend (132) such that the one or more hooks of the arm (134) are aligned with a groove of the plurality of grooves (136) at the desired angle.18)The method of claim 17, wherein locking the at least one of the one or more ratcheting joints (130) of the one or more handle members (120) at the desiredReference No.: BCM 24.03 PCT Inventor’s last name: Kirby, et al. Document Date: August 13, 2025 angle comprises interlocking the one or more hooks of the arm (134) with the groove of the plurality of grooves (136) such that the bend (132) is locked in place at the desired angle.19)The method of claim 15, wherein the plurality of ratcheting joints (130) comprise a first set of joints configured to bend in a first direction and a second set of joints configured to bend in a second direction.20)The method of claim 19, wherein the second direction is opposite the first direction.

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