Surgical Instrument Gearbox With Coupling-Activated Knife Blade Lock

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Solution Overview

Problem

Designing surgical instruments compatible with robotic surgical systems poses challenges due to constraints in the number, type, and configuration of inputs provided by the robotic arm, necessitating innovative mechanisms to optimize functionality.

Innovation Solution

A surgical instrument with a gearbox assembly and a knife blade lock mechanism that allows for controlled translation of a knife blade, featuring a biasing member to maintain the knife blade in a locked position until coupled to a robotic surgical system, enabling precise cutting and grasping operations.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If the knife blade is made movable to enable cutting function, then the cutting capability is improved, but the risk of inadvertent movement and injury during handling is increased

Engineering Contradiction:

Improvecutting capabilityVSAvoidrisk of inadvertent movement

Core Design Contradiction:

Adaptability or versatilityVSObject-affected harmful factors

Solution Approach 1:

The knife blade lock is positioned to engage with the drive input before the instrument is coupled to the robotic surgical system, preventing inadvertent movement during handling and transit. The lock is disengaged only after proper coupling, ensuring the blade is activated only when intended.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The knife blade lock acts as an intermediary mechanism between the drive input and the knife blade, controlling blade movement by engaging or disengaging from the drive input based on coupling status with the robotic system.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If the knife blade lock is engaged to prevent rotation of the drive input, then safety is improved, but the cutting operation cannot be performed

Engineering Contradiction:

ImprovesafetyVSAvoidcutting operation capability

Core Design Contradiction:

ReliabilityVSAdaptability or versatility

Solution Approach 1:

The knife blade lock transitions between a locked position (engaged with drive input teeth) preventing rotation, and an unlocked position (disengaged from drive input teeth) allowing rotation for cutting. This dynamic state change is triggered by coupling to the robotic surgical system.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The lock is engaged in the preliminary state during handling and transit, and only after proper coupling to the robotic system does the mechanism transition to the unlocked state, ensuring safety before operation and functionality during operation.

Inventive Principle:

Principle #10Preliminary action

3Manufacturing precision

If the gearbox assembly is designed with multiple components for precise control, then the precision of cutting and grasping is improved, but the device complexity increases

Engineering Contradiction:

Improveprecision of cutting and graspingVSAvoidgearbox assembly complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The gearbox assembly merges multiple functions (knife blade translation, jaw member actuation, lock mechanism) into a single integrated unit, reducing overall system complexity while maintaining precise control capabilities through shared components.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The drive input serves multiple functions: it can rotate to drive the knife blade when unlocked, and it can be locked by the knife blade lock to prevent rotation. The same component structure supports both cutting and safety functions.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Ensures safe and efficient operation of the surgical instrument by preventing inadvertent movement of the knife blade during handling and transit, ensuring precise cutting and grasping capabilities when interfaced with the robotic system.

Implementation Method 1

a biasing member disposed within the housing and operably coupled to the knife blade lock. The biasing member is configured to bias the knife blade lock into the locked position

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

The annular body portion of the knife blade lock defines a plurality of teeth configured to interlock with a plurality of teeth defined by the drive input when the knife blade lock is in the locked position

Methodology Applied

Scientific EffectMechanical Advantage: Mechanical Advantage

Data Source

PatentUS12376872B2Drive mechanisms for surgical instruments

Publication Date: 2025.08.05 COVIDIEN LP

AI summary

A surgical instrument for use with a robotic surgical system includes a knife blade configured to cut tissue and a knife tube coupled to the knife blade and configured to translate to move the knife blade for cutting tissue. The surgical instrument also includes a gearbox assembly coupleable to a robotic surgical system and configured to translate the knife tube to move the knife blade for cutting tissue and a knife blade lock operably coupled to the gearbox assembly. The knife blade lock is movable from a locked position wherein the knife blade lock prevents translation of the knife tube to an unlocked position in response to coupling of the gearbox assembly to the robotic surgical system wherein the knife tube is permitted to translate to move the knife blade for cutting tissue.