sterile adapters for use in a robotic surgical system

专利摘要:
The invention generally relates to a sterile adapter for use in robotic surgery, which may include a frame configured to be interposed between a tool driver and a surgical tool, a frame assembly coupled to the frame and at least one coupler. supported by the plate assembly and configured to transmit torque from a tool driver output driver to a surgical tool input driver.
公开号:BR112019010317A2
申请号:R112019010317
申请日:2017-12-20
公开日:2019-09-03
发明作者:Bajo Andrea；J Scheib Charles；Hernandez Jaime；J Vakharia Omar
申请人:Verb Surgical Inc；
IPC主号:

专利说明:

Descriptive Report of the Invention Patent for STERILE ADAPTERS FOR USE IN A ROBOTIC SURGICAL SYSTEM.
REMISSIVE REFERENCE TO RELATED DEPOSIT APPLICATIONS [001] This application claims priority over US patent application No. 62 / 436,957, filed on December 20, 2016, and US patent application No. 62 / 436,965, filed in December 20, 2016, and US patent application No. 62 / 436,974, filed on December 20, 2016, and US patent application No. 62 / 436,981, filed on December 20, 2016, each of which here incorporated by reference, in its entirety.
TECHNICAL FIELD [002] The present invention relates, in general, to robotic surgical systems, and more specifically, to new and useful sterile adapters to create a sterile barrier around portions of a robotic surgical system.
BACKGROUND [003] Minimally invasive surgery (IMC), like laparoscopic surgery, involves techniques designed to reduce tissue damage during a surgical procedure. For example, laparoscopic procedures typically involve the creation of several small incisions in the patient (for example, in the abdomen) and the introduction of one or more tools and at least one camera through the incisions in the patient. Surgical procedures are then performed using introduced tools, with the aid of the visualization provided by the camera. In general, CMI provides multiple benefits, such as reduced patient healing, less patient pain, shorter recovery periods and lower medical treatment costs associated with patient recovery.
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2/61 [004] CMI can be performed with non-robotic or robotic systems. Conventional robotic systems, which can include robotic arms to manipulate tools based on an operator's commands, can provide many benefits to IMC while reducing demands on the surgeon. The control of such robotic systems may require control inputs from a user (for example, a surgeon or other operator) through one or more user interface devices that translate (into) user manipulations or commands into system controls robotic. For example, in response to user commands, a tool driver that has one or more motors can drive one or more degrees of freedom of a surgical tool when it is positioned at the surgical site on the patient.
[005] Similar to traditional surgical procedures, it is important to maintain a sterile environment in the surgical field during robotic IMC. However, various components (for example, motors, encoders, sensors, etc.) of the tool driver and other aspects of the robotic surgical system cannot be sterilized in a practical way using conventional sterilization methods, such as by heat. A solution to maintain sterility is to provide a sterile barrier between the tool driver (and other system components that may appear in the surgical field, such as robotic arms, etc.) and the surgical tool, thus providing a non-sterile side for the driver tool and a sterile side for the surgical tool. However, the sterile barrier must not interfere with the way the tool driver drives the surgical tool. In addition, as a tool driver may need to drive different surgical instruments during a surgical procedure, the sterile barrier can facilitate simple and efficient exchange or exchange of surgical tools in a tool driver without
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3/61 promise the sterile barrier. Thus, it is desirable to have new and improved sterile adapters in a sterile barrier for use in robotic surgery.
SUMMARY [006] In general, a sterile adapter for use in a robotic surgical system can include a structure configured to be interposed between a tool driver and a surgical tool, a set of plates attached to the structure and at least one rotating coupler supported by the plate set and configured to transmit torque from a tool driver output driver to a surgical tool input driver. In a variation, the plate set may include a plurality of tool engagement features, wherein each tool engagement feature is engaged with a corresponding adapter engagement feature on the surgical tool. The frame can be configured to attach the surgical tool when each tool engagement feature is engaged with its corresponding adapter engagement feature on the surgical tool. The tool engagement features on the sterile adapter may, for example, include a plurality of recesses and / or protrusions which are arranged in a linear series of progressively increasing length along a direction of insertion of the tool.
[007] In another aspect, the set of plates on the sterile adapter can include at least one contact point. The surgical tool can be configured, for example, to release a directed force along a longitudinal geometric axis of the surgical tool, and the contact point of the sterile adapter can be configured to transmit the force to the tool driver. For example, the contact point may include a rib or other projection on a surface facing the tool driver of the sterile adapter,
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4/61 where the rib is configured to extend into a surface of the tool driver to transfer a force received by the plate set and the rib to the tool driver.
[008] In another aspect, the plate set may include a first face and a second face opposite the first face, the first face of which may include at least one spring that is configured to propel the second face towards the surgical tool. The spring may include, for example, a bundle spring, a coil or spring bundle, or other suitable malleable material to propel the second face of the plate set towards the surgical tool. [009] In general, in other variations, a sterile adapter for use in a robotic surgical system may include a frame, a set of plates attached to the structure and at least one rotating coupler supported by the set of plates and configured to transmit torque from one tool driver output driver to a surgical tool input driver. The coupler may include, for example, a first face that has a first engagement feature configured to engage the tool driver output driver, and a second face that has a second engagement feature configured to engage the tool input driver. surgical. The first and second hitch features can have different shapes. For example, one or both of the coupling features may include a recess to engage a projection on the output driver or input driver (and / or a projection to engage a channel on the output driver or input driver). In another example, the first hitch feature may include an arcuate feature (for example, recess or projection) and the second hitch feature can include a central feature (for example, recess or projection) substantially centered on a geometric axis of
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5/61 rotation of the rotating coupler. The first and second coupling features can extend in opposite axial directions on the coupler (for example, both can be recesses that extend into the coupler body, or both can be projections that extend outwardly from the coupler body. coupler). In addition, the first face of the rotary coupler can include a first set of pin holes for engaging with the output driver of the tool drive, and the second face can include a second set of pin holes for engaging with the input driver of the surgical tool.
[0010] The structure of the sterile adapter may, in other variations, include a body configured to be interposed between a tool driver and a portion of the surgical tool, and a crimp projecting from the body to receive the tool portion surgical. The body of the structure can include a first end and a second end opposite the first end, where, in some variations, an engagement feature can be arranged on the first end of the body to be coupled to a first portion of the surgical tool that suspends the body and / or platform assembly can project (for example, perpendicularly) from the second end of the body to receive a second portion of the surgical tool. A mobile locking member can be included in the sterile adapter and can be selectively operable between an engaged position, in which the locking member secures a frame coupling to the tool driver, and a disengaged position, in which the locking member facilitates a decoupling of the structure from the tool driver. For example, in some variations, the disengaged position can be blocked when the portion of the surgical tool is received in the crimp, thus substantially preventing the sterile adapter from becoming
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6/61 disconnect from the tool driver when the surgical tool is received in the groove.
[0011] A sterile adapter can be part of a sterile barrier system that additionally includes a sterile trim. For example, a sterile barrier for use in a robotic surgical system may include a sterile adapter, including a structure configured to be interposed between a tool driver and a surgical tool, where the structure has a structure perimeter, and at least the projection Peripheral can extend laterally around at least a portion of the perimeter of the structure (for example, as a flange or partial flange). A sterile trim can then be coupled to the projection, such as by means of thermowelding or another suitable coupling process, to form at least part of the sterile barrier system. In some variations, the peripheral projection can include flexible elastomeric material, and the structure and at least one peripheral projection can be injection molded. BRIEF DESCRIPTION OF THE DRAWINGS [0012] Figure 1 is an illustrative diagram of a portion of a robotic surgical system with a tool driver, surgical tool and a sterile barrier.
[0013] Figures 2A to 2C are various perspective views of a variation of a sterile adapter.
[0014] Figure 3A is a perspective view of an exemplary subset of a tool driver and a sterile adapter attached to the tool driver. Figure 3B is a perspective view of an exemplary subset of a tool driver, surgical tool and a sterile adapter interposed between the tool driver and the surgical tool.
[0015] Figure 4A is a perspective view of a variation of a sterile adapter with a bezel. Figure 4B is a view
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7/61 of an exemplary arrangement of a surgical tool coupled to the sterile adapter shown in Figure 4A.
[0016] Figure 5A is an illustrative diagram of a surgical tool in the process of coupling to another variation of a sterile adapter with a curved assembly. Figure 5B is an illustrative diagram of the surgical tool attached to the sterile adapter shown in Figure 5A.
[0017] Figure 6A is a perspective view of a variation of a sterile adapter with a locking member. Figure 6B is a perspective view of an exemplary arrangement of a tool driver and a surgical tool coupled to the sterile adapter shown in Figure 6A. Figure 6C is a perspective view of another variation of a sterile adapter with a locking member.
[0018] Figure 7A is a perspective view of an exemplary arrangement of a tool driver and a surgical tool coupled to a sterile adapter with adjustable drive shaft holes. Figures 7B to 7D are illustrative schemes of various sizes of adjustable drive shaft holes.
[0019] Figure 8 is a cross-sectional diagram of a set of plates with rotating couplers in a variation of a sterile adapter.
[0020] Figure 9A is a perspective view of a variation of a sterile adapter that includes a number of tool engagement features. Figure 9B is a front view of a variation of a surgical tool including a series of adapter engagement features to engage with the series of tool engagement features shown in Figure 9A. Figure 9C is an exemplary angled profile of the adapter hitch features.
[0021] Figure 10A is a view of the front side of a driver
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8/61 example tool. Figure 10B is a perspective view of a variation of a sterile adapter that includes force transfer contiguity features. Figure 10C is a front view of an exemplary surgical driver. Figure 10D is an illustrative cross-sectional view of a tool driver, a sterile adapter with force transfer contiguity features and a surgical tool.
[0022] Figure 11A is a perspective view of a variation of a sterile adapter, including a set of spring-loaded plates. Figure 11B is a cross-sectional diagram of a tool driver, a sterile spring-loaded adapter and a surgical tool.
[0023] Figure 12A is a perspective view of a variation of a sterile adapter, including a peripheral projection. Figure 12B is a perspective view of a sterile barrier, including the sterile adapter shown in Figure 12A.
[0024] Figures 13A and 13B are seen in perspective of a variation of a rotating coupler on a sterile adapter.
[0025] Figure 14A is an exploded diagram depicting the engagement between an output driver for a tool driver, a coupling disc on a sterile adapter and an input driver for a surgical tool. Figure 14B is a cross-sectional diagram of the coupled combination of the components shown in Figure 14A.
[0026] Figures 15A to 15G are illustrative schemes of an exemplary process of coupling a tool driver to a variation of a sterile barrier, and the coupling of the sterile barrier to a surgical tool.
[0027] Figure 16A is a perspective view and a side view, respectively, of another variation of a rotating coupler in
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9/61 a sterile adapter. Figures 16B, 16C and 16D are seen from the side, bottom and top, respectively, of the variation of the rotating coupler shown in Figure 16A.
[0028] Figures 17A to 17C illustrate an exemplary process of coupling a tool driver to a variation of a sterile adapter with a removable film.
[0029] Figures 18A to 18D illustrate an exemplary variation of coupling a tool to another variation of a sterile adapter.
[0030] Figures 19A and 19B illustrate an exemplary variation of the uncoupling of a tool from the variation of a sterile adapter shown in Figures 18A to 18D.
[0031] Figures 20A and 20B illustrate an exemplary variation of coupling a tool to another variation of a sterile adapter.
[0032] Figure 21A is a front view of a variation of a sterile adapter. Figure 21B is a perspective view of a variation of a tool configured to engage the sterile adapter shown in Figure 21 A. Figure 21C is an illustrative scheme of the tool represented in Figure 21B in the process of being attached to the sterile adapter shown in Figure 21 A.
[0033] Figure 22A is a perspective view of a variation of a sterile adapter with drive couplers configured to be magnetically attracted to a variation of a tool driver. Figure 22B is a perspective view of a variation of a surgical tool configured to be magnetically attracted to the sterile adapter shown in Figure 22A.
[0034] Figures 23A and 23B are the anterior and posterior perspective views, respectively, of a variation of a sterile adapter with an axial displacement plate on which the couplers of the
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10/61 sterile adapter are retracted. Figure 23C is a perspective view of an exemplary surgical tool configured to engage with the sterile adapter shown in Figures 23A and 23B. [0035] Figures 24A and 24B are seen in anterior and posterior perspective, respectively, of the sterile adapter shown in Figures 23A and 23B, in which the sterile adapter couplers are extended. Figure 24C is a perspective view of an exemplary surgical tool configured to engage with the sterile adapter shown in Figures 24A and 24B.
[0036] Figures 25A and 25B are seen in perspective from the tool side and the tool driver side, respectively, of another exemplary variation of a sterile adapter. Figure 25C is a tool side view of the sterile adapter shown in Figures 25A and 25B. Figure 25D is a view of the tool driver side of the sterile adapter shown in Figures 25A and 25B. Figures 25E and 25F are the first and second sides of a rotating coupler. Figure 25G is a cross-sectional view of the sterile adapter shown in Figures 25A and 25B.
DETAILED DESCRIPTION [0037] Examples of various aspects and variations of the present invention are described and illustrated here in the accompanying drawings. The following description is not intended to limit the invention to these modalities, but rather to allow one skilled in the art to produce and use the invention.
[0038] As shown generally in the scheme of Figure 1, a portion of a robotic surgical system includes a tool driver 10 configured to actuate a surgical tool 20. One or more drive outputs on the tool driver 10 can, for example , activate one or more trigger inputs in a proximal portion 22 of the surgical tool 20, thus
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11/61 movement (for example, holding, cutting, etc.) of an end actuator located at the distal end of the tool driving shaft 24. In addition, a sterile barrier 100 can be placed between the tool driver 10 and the surgical tool 20, forming a barrier between an internal and non-sterile side, including the tool driver 10, and an external sterile side including the surgical tool 20 which can, for example, be located in a sterile surgical site. The sterile barrier 100 may, for example, include a sterile drape 120 configured to cover at least the tool driver 10, and a sterile adapter 110 coupled to the surgical drape 120 and located between the tool driver 10 and the surgical tool 20. The sterile adapter 110 can be configured to communicate or otherwise transmit actuation forces (for example, rotating torque, linear motion, etc.) from at least one output of the tool driver to at least one input of operating the surgical tool 20. Examples of sterile barriers 100, such as variations of the sterile adapters 110, are described in more detail in the present invention.
Sterile adapter [0039] In a variation, as shown in Figures 2A to 2C, a sterile adapter 200 can include a structure 210 configured to be interposed between a tool driver and a surgical tool, a set of plates 230 coupled to structure 210, and at least one rotary coupler 250 supported by the plate set and configured to transmit torque from a tool driver output driver to a surgical tool input driver.
[0040] In some variations, the sterile adapter can be configured to transmit electrical signals, such as for communication and / or energy (for example, for sensors, etc.), between the trigger
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12/61 tool and the surgical tool. For example, at least a portion of the sterile adapter, such as the frame, plate set and / or at least one rotating coupler, may include metal contacts to transfer electrical signals between the tool driver and the surgical tool. Such metal contacts may, in some variations, be additionally or alternatively used to signal to a controller and / or processor that the sterile adapter is attached to the tool driver and / or to a surgical tool (in other variations, the tool driver and / or the surgical adapter can include any one or more sensors to detect the coupling of the sterile adapter to the tool driver and / or the surgical tool, such as a proximity sensor or a capacitive sensor). Additionally or alternatively, signals and / or energy can be transmitted wirelessly (for example, via Bluetooth or another wireless communication protocol) in any suitable manner. For example, metal contacts can be omitted from the sterile adapter. Structure [0041] In general, the structure 210 of the sterile adapter 200 can provide structural support for the sterile adapter 200, such as for removably attaching the sterile adapter 200 to a tool driver and / or a surgical tool. For example, as shown in Figure 2A, in a variation, frame 210 can include a first engagement feature 212 and / or a second engagement feature 214. As shown in Figures 3A and 3B, the first engagement feature 212 can be configured to couple feature 200 to the first end of a tool driver 10, as including a bead that fits into a corresponding groove in the tool driver through a snap fit or other suitable physical interference. Additionally or alternatively, the first hitch feature 212 may include one or more magnets (not shown)
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13/61 so that the first engagement feature 212 can be guided and / or coupled to a suitable matching feature on the tool driver 10 based on the magnetic attraction between the magnets on the first engagement feature 212 and the magnets on the tool driver. Similarly, the second latching feature 214 can be configured to couple the latch 210 to a second end of a tool driver 10, as with a snap fit or other physical interference, and / or due to magnetic attraction forces. Although Figure 2A represents the first engagement feature 212 and the second engagement feature 214 as being at opposite ends (e.g., a proximal end and a distal end) of the frame and corresponding to the opposite ends of the tool driver, it should be understood that the first hitch feature 212 and / or the second hitch feature 214 can be on side sides and / or any suitable part of frame 210. In addition, less (e.g., one) or more (e.g., three, four, five, etc.) coupling features may be included and distributed between any suitable portions of structure 210, with any suitable geometries (for example, grooves, hooks, flaps, locks, other press fittings, etc.).
[0042] Although the first and second coupling features 212 and 214 are shown in general, as designed, to be coupled to the tool driver by means of pressure fitting, the flaps that extend from one edge of the frame 210, other variations of the latching features or latching features may be included. For example, a surface of structure 210 may include a recess (for example, a channel, groove, hole, etc.) configured to receive and fit with a corresponding projection (for example, crest, pin, etc.) that is in the face outward (drive output) of the tool driver. The reen
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14/61 trance in frame 210 can be dimensioned in relation to the projection to allow the coupling of the tool driver and frame 210 by means of an interference fit. Other characteristics, such as angled barbs on the projection of the tool driver, or elastomeric material conforming to and / or friction on the projection or in the recess, can also facilitate the removable coupling of the sterile adapter to the tool driver. Similarly, as another example, a surface of structure 210 may include a projection configured to receive and engage with a corresponding recess in the tool driver.
[0043] In addition, as shown in Figures 2A and 2B, the structure may additionally include at least one tool engagement feature 216 configured to mate with a portion of a surgical tool. For example, as best shown in Figure 3B, the tool engagement feature 216 may include a groove or other recess configured to receive a hook, lip or other projecting projection, or another feature of the surgical tool 20. In some variations, at least at least one tool hitch feature can be arranged at a proximal end (upper end, as shown in Figure 2B) of frame 210. In addition, at least one tool hitch feature can additionally or alternatively be arranged at one end distal (lower end, as shown in Figure 2B) of structure 210. Like the first and second engaging features 212 and 214 described above, the tool engaging feature 216 can include other variations of features and can be located anywhere structure 210.
[0044] As shown in Figures 2A to 2C, in general, frame 210 may additionally provide structural support for plate set 230. For example, frame 210 may include one or more
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15/61 more slits around the perimeter of the opening in which the plate set 230 is located, so that the edges of the plate set 230 can engage with one or more grooves of the structure 210. The slots can be dimensioned with a suitable amount clearance for the plate set, so that the plate set can move at least in a direction across the plane of the plate set, as described in more detail below. In one variation, the slits can be wider than the thickness of the plate set, so that the plate set 230 can move freely within the slits. In another variation, one or more springs can be present in at least one slot, so that the set of plates 230 moves with some conformity.
[0045] As shown in Figures 2A to 2C, the structure 210 can be generically rectangular, but it can have any suitable shape (for example, rectangular with rounded corners, elliptical, circular, etc.). For example, the shape of frame 210 may correspond to the shape of the tool driver and / or the shape of the surgical tool to which the sterile adapter 200 is intended to be attached. In some variations, the structure can be made, at least partially, from a rigid plastic (for example, polycarbonate, acrylonitrile butadiene styrene (ABS), nylon, a mixture of polycarbonate and ABS, etc.) which may or may not include material reinforcement (for example, carbon fiber or glass reinforcement) and / or additives such as a lubricant additive (for example, polytetrafluoroethylene), talc, etc. The structure can be injection molded, machined, printed in 3D or manufactured by any suitable process.
Sockets [0046] In some variations, the structure of the sterile adapter may include or be attached to a projecting socket to receive and attach to the surgical tool. For example, as shown in the
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16/61
Figures 4A and 4B, a sterile adapter 400 may include a body 410 configured to be interposed between a tool driver and a portion of a surgical tool, and a crimp 420 that projects from the body and is configured to receive the portion of the surgical tool. The crimp 420 can generally assist in coupling the surgical tool to the sterile adapter 400, in that it can serve as a seat or surface to receive the surgical tool 20, so that, when coupled to the sterile adapter 400, the surgical tool 20 can contact the socket 420 for easy and efficient positioning of the surgical tool 20 against the sterile adapter 400 in the arrangement shown in Figure 4B.
[0047] Crimp 420 may include a drive shaft hole 424 configured to receive a drive shaft from tool 24 of surgical tool 20 during and after coupling surgical tool 20 to sterile adapter 400. For example, the shaft hole drive 424 can guide and receive a drive shaft for tool 24 that passes longitudinally through the drive shaft hole 424 and through the bezel 420. In some variations, the bezel 420 may additionally include a drive shaft slot 426 configured to guide and receive a drive shaft of the tool 24 that has passed laterally inward or through the bezel 420 and into the hole of the drive shaft 424. In addition, in some variations, the bezel 420 may include a raised edge 422 or bead that helps to restrict the fitted portion of the surgical tool 22 (for example, by preventing the lateral slide of the surgical tool here). The raised edge 422 can extend around the entire perimeter of the bezel 420, as shown in Figure 4A. Alternatively, the bezel 420 may include multiple projecting tabs similar to the raised rim 422, except for the
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17/61 the fact that the multiple projecting tabs can be distributed at a variety of points around the entire perimeter of the bezel 420 (for example, only in the corners and / or at some point along each edge of the bezel 420). At least a portion of the drive shaft hole 424 and / or the drive shaft slot 426 may include an elastomeric or padded material, where it comes into contact with the drive shaft of the tool 24, which can reduce, by friction, the relative movement between the drive shaft of the tool 24 and the sterile adapter and / or reduce potential damage to the drive shaft of the tool 24.
[0048] The orifice of the drive shaft and / or the drive shaft slot can be adjustable to create a passage to guide different sizes of the drive shaft of the tool 24 through the crimp. In a variation of a sterile adapter 700, as shown in Figure 7A, the bezel 720 may include one or more plugs 722 that adjust the size of the opening (for example, the diameter) of the drive shaft hole to the center (and reduce the degree of misalignment, play or agitation) of tool drive shafts of different sizes 24 passing through the crimp. For example, as shown in Figure 7C, the crimp 720 can include a first plug 722a that defines a passage corresponding to a first diameter of the tool driving shaft and a second plug 722b that defines a passage corresponding to a second diameter of the tool axis. tool drive that is larger than the first diameter of the tool drive shaft. As shown in Figure 7D, the bezel 720 may include a hole in the drive shaft 724 that defines a passageway that corresponds to a third diameter of the drive shaft of the tool that is larger than the first and second diameters of the drive shaft of the tool. Less or more
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18/61 shutters 722 can be included to guide or match less or more sizes of diameters of the tool drive shaft. Each plug can be operable between an inactive position (where the plug passage does not intersect the path of the tool drive shaft 24) and an active position (where the plug passage intercepts the path of the tool drive shaft 24 ). One or more of the shutters can, for example, be configured to slide linearly in and out of the tool driving shaft path 24, or swinging pivotally in and out of the tool driving shaft path 24. One or more of the obturators can be spring-loaded to tilt the obturator towards the driving axis of the tool 24.
[0049] As shown in Figure 7B, at least the first plug 722a can be pushed into its active position, in order to allow a tool drive shaft 24 that has the first diameter of the tool drive shaft ( or smaller) passes through the bezel. The second plug 722b may (or may not) additionally be pushed into its active position to provide a tapered passage to gradually guide the tool drive shaft 24 from the major drive shaft hole 724 into the smaller passage provided by the first shutter 722a. The first plug 722a reduces the amount of possible misalignment and experienced lateral movement of a tool driving shaft 24 with respect to the first diameter of the tool driving shaft and passing through the first plug 722a. As shown in Figure 7C, the first plug 722a can be retracted into its inactive position, and the second plug 722b can be pushed into its active position to allow a drive shaft of the
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19/61 tool 24 that has the second diameter of the tool drive shaft (or that is smaller) passes through the crimp. The second plug 722b reduces the amount of possible misalignment and experienced lateral movement of a tool drive shaft 24 that has the second diameter of the tool drive shaft and passes through the second plug 722a. As shown in Figure 7D, the first plug 722a and the second plug 722b can be pushed into their inactive positions, in order to allow a tool drive shaft 24 that has the third diameter of the tool drive shaft ( or smaller) pass through a hole in the bezel drive shaft 724. The drive shaft hole 724 can be dimensioned to reduce the amount of possible misalignment and lateral movement experienced by a tool drive shaft 24 that has the third diameter of the tool drive shaft.
[0050] In another variation of a sterile adapter that has an adjustable drive shaft hole size for the different tool drive shaft sizes, the bezel may include a radially adjustable plug adjacent to the drive shaft hole that accommodates and adjusts to different diameters of the tool driving shaft. For example, the radially adjustable plug may include a sheet plug with overlapping blades that progressively slide to contract or expand the passage for the tool drive shaft 24. As another example, the radially adjustable plug may include members that extend or which are generally angled radially into the hole of the drive shaft (or which are usually centrally inclined towards the path of the tool drive shaft 24) to center the tool drive shaft
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20/61 ta 24 in the drive shaft hole. The members can, for example, be flexible (such as, bristles, flexible fingers, etc.) so that they can flex less to accommodate smaller tool drive shaft sizes and flex more to accommodate larger drive shaft sizes of the tool. As yet another example, the members can be radially adjustable in length and / or angle (for example, telescopic members, spring-loaded clamps) so that they can extend, retract and / or radially rotate to accommodate different sizes of the axle. tool activation.
[0051] As shown in Figures 4A and 4B, in one variation, the set 420 may include a substantially flat platform to accommodate a flat surface of the proximal portion 22 of the surgical tool 20. However, the set may have any suitable shape, the which can correspond, for example, to the shape of the surgical tool 20 it receives. For example, as shown in Figures 5A and 5B, a sterile adapter 500 may include a socket 520 that is curved (e.g., semicircular) to engage with a corresponding curved surface of the surgical tool 20, similar to a ball and socket joint. Another example of a curved bezel is shown in Figures 25A to 25D, and in Figure 25G. The 2520 crimp includes a central section that is substantially flat, and includes curved side sections that extend beyond either side of the middle section. As shown in Figure 25G, the crimp 2520 can be configured to receive and / or engage with a tool 20, similar to the crimps described above. In addition, the crimping may include multiple components, such as a plurality of extending arms or a multi-membered lattice, which collectively function to pack or otherwise receive the proximal portion of the surgical tool.
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21/61 [0052] As shown in Figures 4A and 4B, in one variation, the bezel 420 can project generally perpendicularly (at about 90 degrees) from the body 410 of the sterile adapter frame. However, the groove 420 can project from the body 410 at any suitable angle, which may depend on the shape of the surgical tool 20 it receives. For example, the profile of the surgical tool portion to be received in the socket may include an angle or curvature along its leading edge, and the socket 420 may be correspondingly angled or curved to receive the surgical tool.
[0053] The bezel 420 may allow multiple techniques to attach the surgical tool to the sterile adapter. Various techniques can be useful, for example, to accommodate different user preferences and / or facilitate easy tool change or exchange when the tool driver is in different positions or orientations (for example, generally vertical, generally horizontal or in other angles) and presents different options for user access to the tool driver. For example, in one technique, a user can guide the surgical tool in a generally longitudinal manner along the frame 410 (and face of the plate set 430), allowing the tool drive shaft 24 to pass longitudinally through the hole in the shaft. drive 424 and / or the drive shaft slot 426 of the sterile adapter. The user can continue to guide the surgical tool longitudinally, until the proximal portion 22 of the surgical tool is accommodated in the groove 420 and / or the flange 23 of the surgical tool engages the engaging feature 416 of the tool driver, thus coupling the tool 20 to the sterile adapter 400 in the arrangement shown in Figure 4B. In another example technique, a user can guide the surgical tool in a generally lateral way towards the face
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22/61 on the tool side of the plate 430, allowing the drive shaft of the tool 24 to pass through the drive shaft slot 426 of the sterile adapter into the drive shaft hole 424. The user can continue to guide the tool surgical side, until at least a portion of the surgical tool comes in contact with the structure 410 and / or the set of plates 430, and then subsequently guide the surgical tool longitudinally until the surgical tool is accommodated in the groove 420. In another exemplary technique , a user can angle the surgical tool in its approach towards the sterile adapter (for example, at 45 degrees in relation to the plate set) and guide the front end of the surgical tool towards the groove 420. Since the proximal portion 22 of the surgical tool is in contact with the bezel 420, the user can tilt the proximal portion 22 back against the c orpo 410 of the sterile adapter until the surgical tool is accommodated in the groove 420. In addition, other techniques for coupling the tool and the sterile adapter may include combinations of aspects of these techniques. Advantageously, the coupling of the tool and the sterile adapter with the aid of a 420 socket is not limited to one technique (for example, only the technique of longitudinally sliding the tool over the sterile adapter), so that a user can select a technique more suitable for him / her, and / or more suitable in a given circumstance where access to the tool driver may be somewhat limited.
[0054] As shown in Figure 4A, the body 410 and the groove 420 can be formed integrally as a part (for example, injection molded, ground, etc.). Alternatively, body 410 and bezel 420 may be formed as separate parts, and bezel 420 may be coupled to the body with fasteners (for example, for
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23/61 spindles), interlocking features, such as interlocking tabs, epoxy or other suitable adhesive, and / or any suitable coupling method.
[0055] In some variations, the sterile adapter may also include a movable locking member to secure the sterile adapter to the tool driver. The locking member can be selectively operable between a engaged position and a disengaged position. In the engaged position, the locking member can attach a frame coupling to the tool driver. In the disengaged position, the locking member can facilitate the decoupling of the tool driver structure.
[0056] For example, in a variation, as shown in Figures 6A and 6B, a sterile adapter 600 can include a locking member 630. The locking member can be coupled to a body 610 and / or a crimp 620 of the adapter sterile 600. Locking member 630 may include at least one end 630a configured to be coupled to the tool driver 10, as with an engagement feature 632 (for example, an opening or recess configured to engage with a projection on the tool driver 10). The locking member 630 may include, for example, a lever which rotates about the geometry axis A to switch between an engaged position and an uncoupled position. In a variation, as best shown in Figure 6B, locking member 630 may also include a second end 630b configured to engage or otherwise come into contact with the tool (for example, second end 630b may include the drive shaft hole 624 through which the tool drive shaft 24 passes when the surgical tool 20 is accommodated in the socket 620), so that the disengaged position is blocked when the surgical tool portion is received in the en
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24/61 spend. Consequently, the locking member 630 can prevent the sterile adapter 600 from uncoupling from the tool driver when the surgical tool is received at the connector. This type of lock can be advantageous, for example, when changing tools to help ensure that the sterile adapter 600 remains in place (for example, to significantly reduce the likelihood that the sterile adapter will be inadvertently decoupled from the tool driver) when surgical tools are exchanged into and out of the sterile adapter frame and bezel. Although locking member 630 is generally shown as a lever in Figures 6A and 6B, it should be understood that, in other variations, other members or mechanisms included in or attached to the sterile adapter may require movement into the space occupied by the tool surgical 20 to uncouple the sterile adapter from the tool driver.
[0057] Alternatively, in another variation, as shown in Figure 6C, locking member 630 'can be configured to switch freely between a freely engaged position and a disengaged position regardless of the presence of the surgical tool. For example, a user can push a projection 634 in the direction indicated by arrow B to disengage the first end 630a from the locking member of the tool driver 10. Similarly, as shown in Figure 25G, a locking member 2531 can be configured to receive and / or engage with at least a portion of the tool driver 10. The locking member 2531 may include a projection 2534 that a user can push to disengage the locking member from the tool driver 10.
Fixing the trim [0058] In some variations, a sterile adapter may include
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25/61 a structure configured to be interposed between a tool driver and a surgical tool, the structure having a structure perimeter and at least a peripheral projection that extends laterally around at least a portion of the structure perimeter . The peripheral projection can provide a surface to which a sterile drape can be attached or secured, so that together the sterile adapter and the sterile drape form a sterile barrier. For example, as shown in Figure 12A, a sterile adapter 1200 can include a frame 1210 configured to be interposed between a tool driver 10 and a surgical tool 20, and a peripheral projection 1260 that extends laterally and around substantially all of the perimeter or contour of the structure 1210. As shown in Figure 12B, a sterile trim 1270 can be coupled to the peripheral projection 1260, as through thermoswelding, thus forming a sterile barrier that can be used to cover the tool driver while allowing , that the tool driver 10 drives the surgical tool 20 through the rotating couplings on the sterile adapter 1200.
[0059] The peripheral projection 1260 can extend a suitable distance to provide sufficient surface area to couple the sterile trim 1270 to the peripheral projection 1260. For example, the peripheral projection 1260 can extend between about 0.2 cm and about 1.5 cm, between about 0.5 cm and about 1.0 cm or between about 0.5 cm and 0.7 cm (for example, about 0.6 cm), etc. to provide sufficient surface area for the thermowelding or other suitable coupling method to connect the sterile trim to the sterile adapter through the peripheral projection.
[0060] In some variations, the peripheral projection 1260 may include a material other than structure 1210. For example, as described above, structure 1210 can be made of a material that is
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26/61 relatively rigid, such as polycarbonate or ABS, while the peripheral projection 1260 may include a relatively more flexible material, such as a malleable elastomer such as a suitable thermoplastic elastomer (for example, MEDIPRENE, SANTOPRENE, etc.). The flexible material of the peripheral projection 1260 can, for example, provide a platform rigid enough to allow the fixation of the sterile trim during the assembly of the sterile barrier (or sufficiently rigid when supported at the rear when fixing the trim with an accessory, etc.) , while being deformable (for example, similar to a living joint) to allow the sterile adapter to be more compact, if necessary (for example, to allow the adjacent or side-by-side placement of multiple tool drivers and / or surgical tools during a surgical procedure, thus advantageously increasing the available positioning and the mobility of the robotic system). The sterile trim can be made of urethane or other suitable material.
[0061] An exemplary method of fabricating a sterile adapter with a peripheral projection includes co-injection molding of a structure and at least one peripheral projection that extends laterally around at least a portion of the perimeter of the structure, and the coupling from a sterile trim to the peripheral projection. Co-injection molding can include introducing a first material into a first portion of a mold corresponding to the structure, and introducing a second material that is less rigid than the first material into a second portion of the mold corresponding to the peripheral projection. The coupling of the sterile trim to the peripheral projection may include heat seal, epoxy or other adhesive, fasteners or any suitable fixation method.
[0062] In some variations, the structure may include multiple layers of peripheral projections. For example, the structure can include
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27/61 include a first peripheral projection and a second peripheral projection overlying the first peripheral projection. The two layers of peripheral projections (each substantially similar to peripheral projection 1260, for example) can be pressed or stapled to the sterile trim. The peripheral projections can be coupled together to secure the sterile trim between the peripheral projections, as with thermosetting, epoxy, etc.
Plate set [0063] The plate set works to provide structural support for one or more rotating couplers (for example, discs, as described in more detail below). For example, as shown in Figures 2A to 2C, for example, the plate assembly 230 can generally be arranged within an opening of the structure 210 and offer structural support for a plurality of rotating couplers 250. In addition or alternatively, the plate assembly it can interact with the tool driver and / or the surgical tool, in order to facilitate alignment, distribute load forces, etc.
[0064] As shown illustratively in a schematic of the cross section of Figure 8, in a variation, a sterile adapter 800 may include a frame 810 and a set of plates 830 disposed within the frame 810. The plate set 830 may include at the minus one opening 840 to receive a rotating coupler 850. For example, the plate set 830 can include six openings 840 to receive six rotating couplers 850, although less (for example, two, three, four or five) or more (for example , seven, eight, nine or ten or more) openings 840 may be included in the plate set 830. The plate set may include multiple layers layered and coupled together. For example, as shown in Figure 8, plate set 830 can include a
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28/61 tool driver side 832 and a tool side plate 842. The multiple plates can be mounted around the rotating couplers 850 so as to contain the couplers 850 inside the openings 840, as by coupling the plate on the 832 tool driver side and on the 842 tool side plate with fasteners (eg screws, etc.), brackets, epoxy or other adhesive, and / or any suitable coupling mechanism. Alternatively, the plate set may be a part formed integrally to include the openings 840. The openings 840 can be sized and shaped to allow the rotating couplers 850 to move across the plane of the plate set (that is, up and downwards in the orientation shown in Figure 8), and / or laterally in general in the plane of the low friction plate set, being further restricted in the 840 opening. The plate set may include, for example, a rigid plastic or other rigid material suitable (for example, polycarbonate, ABS or other materials and compositions described above for the frame, aluminum, stainless steel or other suitable sheet metal, etc.). Like the frame, the plate set can be injection molded, machined, extruded, stamped, 3D printed or manufactured in any suitable manner.
Tool engagement features [0065] In some variations, the plate set may include one or more alignment features that help ensure that the surgical tool is correctly aligned with the sterile adapter before the surgical tool and sterile adapter engage each other. In one variation, the plate set may include a plurality of patterns from one or more tool hitch features (for example, on a tool side plate of the plate set), where each tool hitch feature is adaptable
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29/61 with a matching adapter engagement feature on the surgical tool. For example, at least one tool engagement feature may be adaptable to a corresponding adapter engagement feature in a single 1: 1 pairing, and successful coupling of the paired features may be required to allow the sterile adapter to attach to the tool surgical. In addition, in variations in which all tool engagement features have a single 1: 1 matching with a corresponding adapter engagement feature, the sterile adapter (for example, the frame) can be configured to attach to the surgical tool only when each tool engagement feature is coupled with its corresponding adapter engagement feature on the surgical tool. Each tool hitch feature can include a different groove or size (for example, length, width, etc.) and / or shape (for example, linear, curved, wavy, chamfered or not chamfered, etc.) , and similarly, each of the adapter's engaging features may include an outward projection of different sizes and / or shapes to engage with a respective tool engaging feature on the sterile adapter. In some variations, each (or at least one) of the tool's hitch features may include a projection of different sizes and / or shapes, although each (or at least one) of the adapter's hitch features may include a channel of different sizes and / or formats to engage with a respective tool engagement feature on the sterile adapter.
[0066] In one example, plate set 930 may include recessed tool engagement features 944a, 944b, 944c and 944d, as shown in Figure 9A, and surgical tool 20 may include adapter engagement features that it designs for. out 26a, 26b, 26c and 26d. The tool hitch features 944a, 944b,
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944c and 944d can be configured to exclusively fit the adapter hitch features 26a, 26b, 26c and 26d, respectively. In addition, tool engagement features 944a to 944d can be arranged in a series (for example, sequential pattern or in another pattern), as arranged by increasing the width or length along a tool insertion direction (for example, example, longitudinally along the plate set 930 indicated by the arrow C in Figure 9A), although other patterns may be possible in other variations. Only through the coupling of each of these pairings can the sterile adapter fully attach to the surgical tool 20. Until such a holistic coupling occurs, the coupling features of the adapter projecting outwards 26a to 26d can physically interfere with the the tool side of the plate set 930, thereby driving the plate set 930 and the sterile adapter 950 couplers in the opposite direction of the surgical tool and its inlet couplers 28, thereby preventing coupling between the sterile adapter and the surgical tool. A similar coupling prevention effect can be achieved in a variation in which the tool engaging features 944a through 944d project outward, and the adapter engaging features 26a through 26d are lowered.
[0067] In an exemplary technique for coupling tool 20 to the sterile adapter 900, tool 20 can move longitudinally along plate set 930, with adapter coupling feature 26d meeting tool coupling features 944a, 944b and 944c, in that order, without coupling due to physical interference (for example, by disparities between size and / or shape). Similarly, adapter engagement feature 26c meets tool engagement features 944a and 844b, and adapter engagement feature 26b meets tool engagement feature
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944a without coupling due to physical interference. During this stage, physical interference also pushes against and moves the plate set 930 and its couplers 950 away from the surgical tool 20, thus additionally preventing coupling between the sterile adapter 900 and tool 20. After the tool 20 move further in the tool insertion direction, the adapter engagement feature 26d meets the tool engagement feature 944d, as well as the adapter engagement features 26a to 26c with their respective tool engagement features 944a a 944c. When all of the tool engagement features align and mate with their corresponding corresponding adapter engagement features, the sterile 900 adapter can mate with the surgical tool 20.
[0068] In addition, a projection on the 930 plate set or tool 20 (either as a tool engagement feature or an adapter engagement feature) may have an angled profile (for example, an angled fin) in relation to the direction tool insertion to help reduce physical interference when the surgical tool 20 is sliding along the sterile adapter. For example, as shown in Figure 9C, the adapter engagement features 26a and 26b on the surgical tool can be angled projections away from the tool insertion direction indicated by arrow C in Figure 9A, thus making it easier for the tool to slide into down on the crimp of the sterile adapter. Alternatively, the tool engagement features 944a through 944d on the sterile adapter can be projected outwardly that are angled toward the direction of tool insertion, thus making it easier for the sterile adapter to receive a tool by sliding down over the adapter socket. sterile.
[0069] Although Figure 9A represents a set of 930 cards
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32/61 that has four tool hitch features, in other variations, there may be any suitable number of tool hitch features and adapter hitch features (for example, one, two, three, five, six, seven, eight or more of each). In addition, tool hitch features may vary in width and / or shape. For example, as shown in Figure 25C, plate set 2530 includes two tool engagement features 2544a and 2544b along the length of plate set 2530, with a first tool engagement feature 2544a being shorter and narrower than a second 2544b tool hitch feature. In addition, although the tool engagement features on the sterile adapter are arranged in a linear series of progressively wider width in the variation shown in Figure 9A, in other variations, the tool engagement features may be in other suitable patterns (for example, zigzag, random, radial or concentric, etc.).
Power transfer features [0070] In some variations, the plate set may include one or more contact points configured to transfer the force received by the sterile adapter from the tool. For example, a surgical tool can be configured to apply a directed force along a longitudinal geometric axis of the surgical tool (for example, the direction along the tool drive axis 24), and the axial force can be transferred to the sterile adapter through the coupling between the sterile adapter and the surgical tool (for example, by coupling the adapter engaging features on the tool to the tool engaging features on the sterile adapter, as described above). To prevent the sterile adapter from having to absorb this axial force (which can, for example, damage the structure of the sterile adapter), the adapter
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Sterile 33/61 can include force transfer capabilities that are contiguous with the tool driver, so that axial force is transferred to the tool driver, which can be generally more robust than the sterile adapter and able to withstand these forces without suffering damage.
[0071] One or more of the contact points may be an outward projection onto a plate on the side of the tool driver of the plate set that fits into a recess in the tool driver 10. Additionally or alternatively, one or more of the points contact may be a recessed wall in the plate on the tool driver side of the plate set configured to receive an outward projection onto the tool driver 10. For example, as shown in Figure 10B, a sterile adapter 1000 may include a set of plates 1030 with one or more ribs projecting outwardly, such as ribs 1034a and 1034b. The ribs 1034a and 1034b can engage and abut the receptacles 14a and 14b, respectively, which are shown in Figure 10A. Consequently, when the tool driver 10, the sterile adapter 1000 and the tool driver 20 are engaged together, the axial forces experienced by the tool 20 can be released to the sterile adapter 1000 (for example, through the attachment features of the adapter 26a to 26c) and subsequently transferred to the tool driver 10 (for example, through the ribs 1034a and 1034b). Similar to the tool engagement features 944a to 944d, and / or the adapter engagement features 26a to 26d described above with reference to Figure 9B, the outwardly protruding ribs 1034a and / or 1034b can be elongated and angled in profile , although they can have any suitable shape that has sufficient surface area to be contiguous with the tool driver.
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34/61 [0072] Figure 10D illustrates a variation in which the contact points (for example, the ribs) of the plate set can separate or redirect axial forces from the tool to the tool driver. The adapter engagement features 26c and 26d on the surgical tool 20 can engage the tool engagement features 1024c and 1024d (which may be similar to the tool engagement features 944a through 944d described above) on the sterile adapter, so that the plate set receives the axial force released by the tool (for example, the forces in the direction of arrow D) through the tool engagement features 1024c and 1024d. Movement of the plate set is prevented, at least in part, by touching the ribs 1034a and 1034b against receptacles 14a and 14b, which also results in the transfer of axial force from the sterile adapter to the tool driver 10. In some variations, at least some of the tool engagement features on the sterile adapter, such as the tool engagement features 1024c and 1024d, may be aligned with the ribs 1034a and / or 1034b to provide a more direct path for transferring forces from the tool to the tool driver. For example, as shown in Figure 10D, the tool engagement feature 1024c is aligned with the rib 1034b. In other variations, the tool hitch features do not need to be aligned with the force transfer contact points.
[0073] Such an axial force transfer can, for example, prevent potentially harmful loads from being transferred to the structure 1010 of the sterile adapter 1000. Consequently, the structure 1010 can be advantageously smaller and lighter, since it does not need to be robust enough to withstand axial force. In addition, in some variations, the force transfer capabilities on the sterile adapter may result in less compliance or clearance in the sterile adapter.
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35/61 tool driver, in the sterile barrier and in the surgical tool set as a whole, as well as in a more precise performance of the surgical tool by the tool driver (especially when the tool is experiencing force loads).
Springs [0074] The plate set may, in some variations, include one or more springs configured to urge or tilt the plate set towards the surgical tool 20 and in the opposite direction to the tool driver 10. For example, as shown in Figure 11A, a sterile adapter 1100 may include a set of plates 1130 including a plurality of springs 1136 located on a plate on the tool driver side of the plate set 1130. Springs 1136 may include, for example, a beam spring , a spiral spring, a spring bundle, a malleable material (for example, an elastomeric material) and / or any suitable mechanism or material that provides a deformation-resistant spring force. In some variations, one or more of the 1136 springs can be formed integrally with the 1130 plate assembly (for example, through injection molding). As shown in Figure 11B, when the tool driver 10, the sterile adapter 1100 and the surgical tool 20 are assembled together, the springs 1136 can be configured to tighten the surface facing the sterile adapter of the tool driver 10 and push the assembly of plates 1130 away from the tool driver 10, thus placing the plate set 1130 closest to the surgical tool 20.
[0075] One or more 1136 springs can, for example, help to stimulate the coupling between the sterile adapter and the surgical tool before the sterile adapter 1150 rotary couplers fully engage with the surgical tool input driver ( not shown), such as to help prevent the tool
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36/61 the surgical plate completely separate (for example, fall) from the sterile adapter. As another example, the spring can help to keep the 1150 rotating couplers positioned within the plate set with a clearance gap, in order to avoid the friction of the 1150 couplers' ribs against the surfaces of the plate set during tool activation. The operation of one or more springs in the plate set is further described below in relation to the engagement and disengagement sequence of the rotating couplers of the sterile adapter with the tool driver and the surgical tool.
Rotating couplers [0076] The rotating couplers (for example, the coupling discs) are supported by the plate set as described above. Rotary couplers are configured to transmit torque from a tool driver to a surgical tool. Each coupler can include, for example, a body (for example, a disc) configured to be interposed between a tool driver output driver and a surgical tool input driver. The body may include a first face that has a first engagement feature configured to engage the output of the tool driver driver, and may further include a second face that has a second engagement feature configured to engage the surgical tool input driver. . The first and second hitch features can have different shapes. For example, in some variations, the body may include a first face that defines a first recess and a second face that defines a second recess, in which the first recess and the second recess have different shapes. As another example, in some variations, the body may include a first face that has a first projection and a second face, which has a second projection, the first and second projections having different shapes. In some
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37/61 variations, the body can include a first face that has a first arcuate feature (for example, channel or projection) configured to engage the tool driver output driver, and can also include a second face that has a second feature arcuate (for example, channel or projection) configured to engage the surgical tool input driver. The first and second arcuate features can have different arc lengths.
[0077] In an exemplary variation, the body may include a face on the side of the tool driver 1310, as shown in figure 13A, and a face on the side of tool 1350, as shown in figure 13B. The side face of tool driver 1310, as shown in Figure 13A, can include a first arcuate feature 1312 and one or more first face features of tool 1314. The side of tool side 1350, as shown in Figure 13B, can include a second arcuate feature 1352 and one or more second drive features 1354. Each of the first and second arcuate features 1312 and 1352 can, for example, be a circular segment. In addition, the first and second arcuate features 1312 and 1352 can be circular segments (for example, having a C shape) that are centered around a geometric axis of rotation of the body. In a variation, the first and second arcuate features 1312 and 1354 are arcuate channels for engaging outward projections onto the tool drive output driver and the surgical tool input driver. However, it should be understood that, in addition or alternatively, the face of the tool driver side 1310 and / or the face of the tool side 1350 may include an outward projection that engages a corresponding arcuate channel in the driver output driver tool or in the surgical tool input driver.
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38/61 [0078] The arcuate features 1312 and 1354 rotate the rotating couplers to engage with the tool driver and the surgical tool. For example, arcuate features may work, at least partially, to ensure that there is a single rotational orientation of the 1300 rotary coupler with respect to an output driver for a tool driver and an input driver for a surgical tool. As best shown in Figure 14A, the first arcuate feature 1312 on the side of the tool driver side of the coupler body can be configured to fit with a corresponding arcuate feature 1416 on an output driver 1412 of a tool driver. For example, the arcuate feature of the coupler 1312 and the arcuate feature of the output driver 1416 can sweep at approximately equal angles, so that there is only one relative rotational position where the arcuate feature of the coupler 1312 and the arcuate feature of the output driver 1416 can couple and engage. Similarly, as shown in Figure 14A, the second arcuate feature 1352 on the tool side face of the coupler body can be configured to fit with a corresponding arcuate feature 1424 on an inlet driver 1422 of a surgical tool. For example, the arcuate feature of the coupler 1252 and the arcuate feature of the input driver 1426 can sweep approximately equal angles, so that there is only one relative rotational position in which the arcuate feature of the coupler 1352 and the arcuate feature of the input driver 1426 can couple and engage. When output driver 1412 is coupled to input driver 1422 via rotary coupler 1300, as described above and shown in the cross-sectional view in Figure 14B, rotary coupler 1300 can transmit torque from the output driver to the tool driver for the initiative
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39/61 surgical tool inlet, so that the tool driver activates or pushes the surgical tool.
[0079] The first and second arcuate features can have different arc lengths. In addition, the sum of the central angle swept by the first arcuate feature 1312 and the central angle swept by the second arcuate feature 1352 can be equal to about 360 degrees, or a full circle. For example, one of the arcuate features on the body (for example, the first arcuate feature 1312) can sweep a main arc, (that is, a large arc more than 180 degrees, such as an angle that is between about 181 degrees and about 270 degrees), while the other arcuate feature (for example, the second arcuate feature 1354) on the body can sweep a smaller arc (that is, a small arc less than 180 degrees, as an angle that is between about 90 degrees and about 179 degrees). In variations where one of the first arcuate feature 1312 or the second arcuate feature 1352 sweeps a main arc that is more than 180 degrees and the other sweeps a smaller arc that is less than 180 degrees, the first and second arcuate features can help to maintain rotation in the plane of the 1300 coupler during activation. For example, with reference to Figure 14A, when the arcuate feature of output driver 1416 is received at the first arcuate feature of coupler 1312 and the arcuate feature of input driver 1426 is received at the second arcuate feature of coupler 1352, the driver disk output 1412 and the input driver disk 1422 can be substantially prevented from tilting or bending towards each other due, at least in part, to physical interference between the arcuate feature of the output driver 1416 and the arcuate feature of the input driver 1426 through the interspersed surfaces of the arched features of the coupling disc 1300. In this way, the coupler 1300 can maintain full movement
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40/61 substantially (for example, without precession), which also helps to keep the output driver disc 1412 and the input driver disc 1422 substantially parallel, thereby improving the accuracy of the surgical tool's performance.
[0080] The side of the tool driver side 1310 can also include one or more first features of driver 1314, as shown in Figure 13A, and the face facing tool 1350 can additionally include one or more second tool features drive 1354, as shown in Figure 13B. The drive features 1314 and 1354 can include, for example, pin holes or recesses (square, round, etc.) configured to engage with drive pins that project outwardly over the tool driver's output driver and over the input trigger of the surgical tool. However, it should be understood that, in addition or alternatively, the face of the tool driver side 1310 and / or the face of the tool side 1350 may include an outwardly extending driver pin that engages a corresponding hole or recess on the output driver of the tool driver or on the input driver of the surgical tool. In addition, drive features 1314 and 1354 can include chamfers to help guide engagement with the corresponding drive features in the tool driver and / or the surgical tool. In a variation, the body includes two actuating features 1314 on its face on the side of the tool driver arranged about 180 degrees from each other, and two actuating features 1354 on its face on the tool side arranged about 180 degrees one of the other. The set of the two drive resources 1314 and the set of the two drive resources 1354 can be rotated by about 90 degrees (for example, a first drive resource 1314 located at about 0 degrees, one if
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41/61 (second drive resource 1354 located at about 90 degrees, another first drive resource 1314 located at about 180 degrees and another second drive resource 1354 located at about 270 degrees). A rotational displacement of about 90 degrees can, in some variations, allow and help to compensate for axial misalignment between the tool driver output driver and the surgical tool input driver (for example, operating in a similar manner to a disk floating in an Oldham coupler). In addition, the first drive resources 1314 may, in some variations, be equidistant from the coupling axis of rotation 1300 and similarly, the second drive resources 1354 may be equidistant from the coupling axis of rotation.
[0081] The first and second drive resources 1314 and 1354 can be arranged close to the edge or perimeter of the coupler body, in order to maximize the torque transferred from the tool driver to the surgical tool through the 1300 coupler. For example, with Referring to Figure 14A, the first drive features 1314 (not shown in Figure 14A) on coupler 1300 can be configured to receive pins from output driver 1414 on output driver 1412. The second drive features 1354 on coupler 1300 can be configured to receive input driver pins 1424 on input driver 1422. Therefore, when output driver 1412 is coupled to input driver 1422 via rotary coupler 1300, as shown in the cross-sectional view in Figure 14B, the 1300 rotary coupler can transmit torque from the tool driver output driver to the tool input driver then surgical, so that the tool driver activates or pushes the surgical tool. Although the 1314 and
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1354 on the coupler 1300 can be the main resources for transmitting torque, the arcuate features 1312 and 1352 on the coupler 1300 can also transmit some amount of torque by virtue of also engaging with the output driver of the tool driver and the driver of the surgical tool. [0082] As shown in Figures 13A and 13B, the coupler body can additionally include an external flange 1360 that helps to retain and / or position the coupler 1300 within the plate set. The outer flange 1360 may be substantially continuous around the perimeter of the coupler body, although, alternatively, it may include distinct segments (e.g., flaps) distributed around the perimeter of the coupler body. In addition, the outer flange 1360 can include one or more frictional features, such as on the side of the 1350 tool side of the outer flange 1360, which can help reduce the amount of free rotation of the 1300 coupler within the plate assembly, when desired (for example, during selected parts of the coupling process, where the 1300 coupler engages the surgical tool, as described in more detail below). In some variations, the face of the tool driver side 1310 of the outer flange 1360 may, additionally or alternatively, include one or more frictional features. Examples of frictional features include 1370 protrusions, as shown in Figure 13B, a corrugated or corrugated outer flange profile, an elastomeric material or other material with a high friction coefficient (e.g. blocks, co-jetted, overmoulded, etc.) on the flange external 1360, etc.
[0083] As shown in Figures 16A and 16B, another exemplary variation of a rotating coupler 1600 on a sterile adapter (for example, for placement in a displacement plate assembly) may include a first 1610 coupling portion configured to engage to an external trigger from a trigger
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43/61 tool and a second 1650 coupling portion configured to engage a surgical tool input driver. The first and second coupling portions 1610 and 1650 can be separate parts that are coupled or attached together (for example, with epoxy or other suitable adhesive, thermal molding, pressure or pin adjustment, or other joining features, etc.) . Alternatively, the first and second coupling portions 1610 and 1650 can be formed integrally, as through injection molding, or machined, as a part.
[0084] Similar to the rotary coupler 1300 described above with reference to Figures 13A and 13B, the rotary coupler 1600 can incorporate one or more arcuate features (for example, at least one recess and / or projection outward by sweeping a main arc, or appearing in a C format) to provide a single rotational alignment with respect to an output driver disk in a tool driver and with respect to an input driver disk in a surgical tool. Arched features can also help keep the 1600 coupler rotating substantially in a single plane. In addition, similarly to the rotary coupler 1300, the rotary coupler 1600 can incorporate drive features (for example, pins located as far away as possible from a central axis of rotation of the coupler body) to transmit the drive torque of a drive output on a tool driver to an input driver on a surgical tool. In addition, like the rotary coupler 1300, the rotary coupler 1600 can include an outer flange 1660 configured to help retain and position the rotary coupler 1600 within a set of plates.
[0085] For example, Figure 16C represents a face on the side of the tool driver (that is, configured to face
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44/61 and engaging the tool driver) of the first portion of the 1610 coupler. The side of the tool driver side of the first portion of the 1610 coupler can include an arcuate feature 1612 configured to engage with a corresponding arcuate feature on a tool driver (not shown) and drive features 1614 (for example, holes) configured to engage with the corresponding drive resources (for example, pins) on the tool driver. In addition, Figure 16D represents a face on the tool side (i.e. configured to face and engage the surgical tool) of the second portion of the 1650 coupler. The tool side face of the second portion of the 1650 coupler may include a 1652 arcuate feature configured to engage with a corresponding arcuate feature on a surgical tool (not shown) and 1654 drive features (for example, holes) configured to engage with the corresponding drive features (for example, pins) on the surgical tool.
[0086] In some variations, the first drive features of the coupling portion 1614 can be displaced about 90 degrees from the second drive features of the coupling portion 1654. For example, the first and second portions of the coupler 1610 and 1650 can be different examples of the same design (for example, the same size and shape), but rotated and fixed to each other with a rotational displacement of approximately 90 degrees. This rotational displacement can allow and help to compensate for axial misalignment between the tool driver output driver and the surgical tool input driver (for example, operating similarly to a floating disk in an Oldham coupler). At least some of the drive features in the coupler 1600 can be elongated or slotted, which can provide a degree of tolerance to accommodation and
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45/61 compensation for axial misalignment between the tool driver output driver and the surgical tool input driver. For example, the drive features 1614 in the first coupling portion 1610 can be, to some degree, elliptical to allow the coupler 1600 to translate around a circular driver pin on the tool drive as the coupler 1600 rotates, while in addition, the drive features 1654 in the second portion of the coupler 1650 may be somewhat elliptical to allow the coupler 1600 to translate around a circular pin of the driver on the surgical tool. In this way, drive features 1614 and 1654 may be able to compensate for axial misalignment.
[0087] Another exemplary variation of a 2550 rotary coupler on a sterile adapter (for example, for placement on a set of displacement plates) is shown on the sterile adapter 2500 shown in Figures 25E and 25F. A first face (for example, the face on the tool driver side) of the rotary coupler 2550 is shown in Figure 25E, while a second face (for example, the face on the tool side) of the rotary coupler 2550 is shown in Figure 25F . In addition, the rotating coupler 2550 may include an outer flange 2560 similar to the outer flange 1360 described above with reference to Figures 13A and 13B. As shown in Figure 25G, one or more rotary couplers 2550 can be supported by a set of plates 2530 in a structure 2510 similar to that described elsewhere in the present invention.
[0088] As shown in Figure 25E, the first face of the rotating coupler can include at least one 2562 coupling feature to engage with a tool driver output driver. The 2562 hitch feature may include a central feature (for example, a recess or projection) that is substantially centered on
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46/61 a geometric axis of rotation of the rotating coupler. As shown in Figure 25F, the second face of the 2500 rotary coupler can include at least one 2564 hitch feature. The 2564 hitch feature can include an arcuate feature (for example, recess or projection, such as an arcuate channel or arcuate projection). similar to those described above with respect to couplers 1300 and 1600. As shown in Figure 25F, the second face of the 2500 rotary coupler can include two coupling features 2564 and 2564 '(for example, a coupling feature arranged on each side of a feature actuator 2574 described below). In other variations, the 2500 rotary coupler can include any suitable number of engagement features on the first side and / or the second side of the 2500 coupler.
[0089] In some variations, the coupling features 2562 and 2564 may extend in opposite axial directions. For example, as best shown in the perspective views of Figures 25A and 25B, both engagement features 2562 and 2564 can be recesses (for example, channels) that extend inwardly in opposite directions on the rotating coupler. Alternatively, the engagement features 2562 and 2564 can be projections (for example, ridges) that extend outward in opposite directions on the rotating coupler.
[0090] In some variations, the 2550 coupler may include one or more drive features (for example, similar to the drive features described above for coupler 1300 and coupler 1600). For example, similar to coupler 1300, the face of the coupler on the driver side 2550 shown in Figure 25E can include one or more first drive features 2572 (for example, cutouts), and the coupler face on the tool side 2550 shown in Figure 25F can include one or more 2574 actuation seconds (for example, cutouts). The 2572 drive feature set and the 2574 drive feature set can be moved
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47/61 rotating by about 90 degrees, similarly to that described above in relation to the 1300 coupler. However, the drive resources can be dimensioned, shaped and arranged in any suitable way.
[0091] Rotating couplers (for example, coupler 1300, coupler 1600, coupler 2550) may include polycarbonate, ABS, other materials described above for the frame and / or set of plates or other suitable rigid material that can be molded injection, machined, extruded, stamped, 3D printed or manufactured in any suitable manner.
Coupling and uncoupling of the sterile adapter [0092] An exemplary method for coupling and engaging the sterile adapter described above with a tool driver and / or a tool unit is generally depicted in Figures 15A to 15G. As shown in Figure 15A, a sterile adapter can include a frame 1520 that houses a set of plates 1510. The plate set 1510 can include a plate on the tool driver side 1512 and a plate on the tool side 1514, and the assembly of plates can support one or more couplers or 1300 rotating coupler discs arranged between plates 1512 and 1514 with adequate axial and rotational clearance. In addition, a tool driver 1410 may include one or more discs of output driver 1412 configured to mate and engage with one or more corresponding 1300 coupling discs.
[0093] In Figure 15A, frame 1520 is attached to tool driver 1410, but as shown in more detail in Figure 15B, output driver 1412 discs are not yet engaged with coupling discs 1300. As shown in Figure 15B, the output driver disk 1412 is tilted upward against the disk of the coupler 1300 due to a tilt force (for example,
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48/61 example, provided by a spring in the tool driver that spring drives the output driver disc 1412 and / or at least one magnet that causes an attraction between the output driver disc 1412 and the coupling disc 1300). The coupling disc 1300 is also propelled upwards, with its movement limited by the outer flange 1370 of the coupling disc 1300 being constricted by the plate on the tool side 1514.
[0094] After fixing the structure 1520 to the tool driver 1410, the output driver disk 1412 rotates (for example, driving a motor coupled to the output driver disk 1412) until its arched feature 1426 is rotatable aligned with the arcuate feature of the coupling disc 1312. Despite some amount of frictional contact between the output driver disc 1412 and the coupling disc 1300 which may tend to cause discs 1412 and 1300 to move together, the frictional features on the outer flange 1360 they can substantially prevent the coupling disc 1300 from rotating together with (for example, in conjunction with) the output driver disc 1412 as the output driver disc rotates. For example, frictional features (for example, the raised projections 1360, as described above with reference to Figure 13B) that scrape against the tool side plate 1514, can substantially prevent the coupling disc 1300 from rotating while the actuator disc output 1412 rotates in an effort to achieve rotational alignment with the coupling disc 1300. For example, a processor can be coupled to the tool driver and configured to control one or more discs of the output driver 1412 (simultaneously, individually in sequence, in pairs, etc.) to rotate until they are pivotally aligned and engaged with their corresponding 1300 rotating coupling discs. In some variations, rotational alignment can be achieved by driving the discs
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49/61 of output driver 1412 until each has rotated at least a predetermined angle or number of revolutions (for example, 1, 1.5, 2, 2.5, 3 etc.) or for a predetermined period of time . At some point during a limit angle or number of rotations, each disc of the moving output driver 1412 will be pivotally aligned with the substantially static rotating coupling disc 1300. Additionally or alternatively, the rotational alignment can be determined, for example, with sensors (capacitive, etc.) located on one or both sides of the interface of the output driver discs and the 1300 rotating coupling discs, so that an intimate and adjacent contact is detected between the output driver discs and the coupling discs rotating. As yet another example, the rotating alignment can be detected based on the reaction torque measured by one or more sensors in the tool driver when an output driver disc 1412 becomes engaged with its corresponding coupling disc 1300. Once this alignment rotational is achieved, the arcuate feature 1416 engages the arcuate feature of the coupling disc 1312 (and the pins of the output driver disc 1412 also engage with the drive capabilities of the coupling disc 1300), at least in part because the output 1412 is forced against the coupling disc 1300.
[0095] In Figure 15D, a surgical tool 1420 is attached to the sterile adapter (for example, to the structure and / or plate set 1428) moving along the sterile adapter in the direction shown by arrow E. The surgical tool 1420 attaches to the sterile adapter when all of the engagement features of the 1428 adapter on the tool (for example, a rib similar to the ribs 26a to 26d described above with reference to Figure 19B) engage with all corresponding tool engagement features 1515 on the
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50/61 plate set, as partially shown in Figure 15E. [0096] As shown in Figure 15E, the output driver disk 1412 and the coupling disk 1300 are still engaged. The input drive 1422 discs on the surgical tool are not yet engaged with the 1300 coupling discs and, therefore, they tend to push the 1300 coupling discs and the plate set down due to not engaging. To provide a counter force, the displacement plate assembly (including plates 1512 and 1514) is tilted up against the surgical tool 1420 by one or more springs on the displacement plate assembly (for example, spring 1136, as described above, with reference to Figures 11A and 11B), thus causing the coupling disc 1300 to be pressed against the plate on the side of the tool driver 1512 and creating an upper gap between the coupling disc 1300 and the input driver disc 1422 of the tool. In addition, the springs on the displacement plate assembly encourage engagement of the plate assembly with one or more adapter 1428 engaging features on the tool, thereby helping to prevent the surgical tool 1420 from falling out of the sterile adapter.
[0097] After attaching the surgical tool 1420 to the sterile adapter, the coupling discs 1300 can rotate (simultaneously or individually in sequence, etc.) by rotating the discs of the output driver 1412 in an effort to achieve rotational alignment with the corresponding input driver disks 1422 in the surgical tool. Rotational alignment between coupling discs 1300 and corresponding input driver discs 1422 can occur and / or be detected, for example, in the same or similar way as the rotational alignment between discs of output driver 1412 and coupling discs 1300 described above. This rotational alignment is achieved when all resources arch
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51/61 of the 1426 on the 1422 tool input drive disks are aligned with the corresponding arcuate features 1352 on the coupling disk 1300 (and the drive pins 1424 on the input coupler disk 1422 are aligned with the 1354 drive resources on the disks 1300 couplers). Prior to this step, any rotational misalignment between a coupling disc 1300 and a corresponding input driver disc 1422 will tend to push coupling discs 1300 and the plate set down. For example, as shown in Figure 15F, the coupling disc 1300 'shown on the left is not yet pivotally aligned with its corresponding input driver disc 1422, while the coupling disc 1300 shown on the right is pivotally aligned with the its corresponding input driver disk 1422.
[0098] When all the 1300 coupling discs are pivotally aligned with the corresponding input driver discs 1422, then the 1300 coupling discs engage with the output driver discs 1412 on the tool driver and are engaged with the input driver 1422 disks in the surgical tool, as shown in the arrangement shown in Figure 15G. In addition, the bias springs on the plate set 1510 push the plate set 1510 up against the tool. As a result, the coupling disc 1300 is generally centered within the plate set 1510, where it has an upper and lower clearance to rotate within the plate set freely (for example, so that the friction protrusions on the outer flange of the coupling disc do not come into contact with any surface). Consequently, the coupling discs 1300 are ready to transmit the torque from the output driver discs 1412 to the input driver discs 1422 through the sterile barrier of which the sterile adapter is part.
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52/61 [0099] To detach the surgical tool from the sterile adapter, a lock (for example, a lever or button mechanism) on the surgical tool can work to press or push the displacement plate assembly downwards away from the tool surgical. When the displacement plate set is sufficiently pressed, the 1300 coupling disks are separated and disengage from the disks of the input driver 1422 of the surgical tool, thus allowing the surgical tool to be removed from the sterile adapter. In addition, the sterile adapter frame can be unlocked (for example, by disengaging a locking mechanism such as locking mechanism 630 described above with reference to Figure 6A or locking mechanism 630 'described above with reference to Figure 6C) from from the tool driver, and then lifted to separate and disengage the coupling discs 1300 from the output driver discs 1412 of the tool driver, thus allowing the sterile adapter to be removed from the surgical tool.
Coupling and uncoupling variations [00100] In some variations, the sterile adapter may additionally or alternatively include a removable film to help guide the rotating couplers to the sterile adapter, such as when engaging the output driver discs with the tool driver with the rotating couplers on the sterile adapter. For example, the coupling discs on the sterile adapter can be pre-aligned with a removable film before and during fixing the frame to the tool driver. For example, as shown in Figure 17A, a 1700 sterile adapter can include a removable film 1702 on one side of the sterile adapter tool that adheres to the 1710 coupling discs and maintains the drive capabilities of the 1712 coupling disc in a predetermined orientation. Before connecting the adapter
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53/61 sterile 1700 to the tool driver 1720, the output driver 1722 discs can be rotated (for example, by driving the motors coupled to the output driver 1722 discs) for a predetermined orientation. For example, the output drive 1722 discs can be rotated to be aligned in a longitudinal or axial direction along the tool, as shown in Figure 17B, and / or rotated to match the predetermined orientation of the 1710 coupling discs. the sterile barrier 1700 to the tool driver 1720, the removable film 1702 can keep the coupling discs 1712 substantially stationary, so that the discs of the output driver 1722 can be rotated to seek rotational alignment with the coupling discs 1712. Once achieved the rotating alignment, the removable film 1702 can be removed (for example, rubbed, scraped, etc.), as shown in Figure 17C. Removable film 1702 can include, for example, polyurethane, polyethylene terephthalate (PET) and / or any suitable material fixable with a pressure sensitive adhesive or other suitable adhesive. In some variations, the 1702 removable film can also function as protection for the sterile adapter, such as during transport or storage.
[00101] In some variations, the coupling of a surgical tool to a sterile adapter may involve selectively exposing the adapter's rotating couplers to couple and, selectively, covering them to uncouple them from the surgical tool) due to an over or actionable lock by a surgical tool. For example, in a variation, as shown in Figure 18A, a 1730 surgical tool can include at least one lever 1732 that is actuable (for example, by tightening the levers on both sides of the 1730 surgical tool). As shown in Figure 18D, when the 1732 levers are pressed inward, the arms of the wingPetition 870190047448, of 5/21/2019, p. 61/141
54/61 van 1734 are configured to push down and move at least the rotating couplers of the 1710 sterile adapter. Consequently, when the 1730 surgical tool is sliding over the sterile adapter, as shown in Figure 18B, the levers 1732 can be pressed inward to substantially prevent engagement between the 1710 rotary couplers and the tool driver input drives (not shown). As shown in Figure 18C, when the surgical tool 1730 is sufficiently accommodated in the sterile adapter, the levers 1732 can be released, thus moving the lever arms 1734 away from the sterile adapter 1700 and allowing the sterile adapter rotary couplers 1710 ( tilted upwards, as described above, as with springs or magnets) move upwards and engage with the surgical tool inlet drivers. In addition, each lever 1732 can include at least one lever foot 1736 configured to rest in a side cutout 1706 (shown in Figure 18B) on the sterile adapter 1700 to continue to allow the 1710 swivel couplers to tilt upward, maintaining thereby engaging the tool input driver with the rotary couplers on the 1710 sterile adapter.
[00102] The 1730 surgical tool can be detached from the 1700 sterile adapter by reversing the coupling process described above. For example, as shown in Figure 19A, levers 1732 can be pressed inward, thus moving lever arms 1734 (not shown) to push down and move the rotating couplers on the 1710 sterile adapter (not shown). The displacement of the 1710 rotating couplers causes the 1730 tool input drives to disengage from the sterile adapter, which allows the 1730 surgical tool to be removed, as shown in Figure 19B.
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55/61 [00103] Figures 20A and 20B illustrate another variation to selectively expose and hide the sterile adapter's rotating couplers due to a lock over or actuating by the surgical tool. As shown in Figure 20A, a sterile adapter 2000 can include a displacement plate 2022 that is spring-loaded to be tilted upward towards the surgical tool 2030. Displacement plate 2022 can be limited against the spring load by a locking lever 2020 in a engaged position, so that the displacement plate 2022 limits the rotary coupler 2010 in a stowed position, which is also spring-loaded and tilted upwards towards the surgical tool 2030. While the lever is in position shown in Figure 20A and the rotating coupler 2010 is retracted or hidden, the rotating coupler 2010 is not able to engage with the 2032 inlet driver disk of the 2030 surgical tool. The surgical tool can approach to be accommodated in the sterile adapter 200 ( for example, moved in the direction of arrow F) until you find the locking lever 2020. The locking lever 2020 rotates p for a disengaged position as shown in Figure 20B, thus releasing the inclined displacement plate 2022. The displacement plate 2022 is inclined to move upwards towards the surgical tool, thus allowing the rotary coupler 2010 to also extend upwards towards the 2030 surgical tool and engage the 2032 input driver disk. After engaging the 2010 rotary coupler and the 2032 input driver disk, the 2010 rotary coupler can be driven and transmit the torque to the 2030 surgical tool.
[00104] The 2030 surgical tool can be detached from the sterile adapter 2000 by reversing the coupling process described above. For example, a locking mechanism (not shown) can push down on a member of the 2024 offset plate
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56/61 until the locking lever 2020 is restored to its engaged position shown in Figure 20A, to which the locking lever 2020 restricts the displacement plate 2022 and again retracts the rotary coupler 2010. After the retraction of the rotary coupler 2010, the rotary coupler 2010 is detached from the surgical tool 2030, so that the surgical tool 2030 can be removed. Axial mounting variation of the displacement plate [00105] In another variation, as shown in Figures 21A to 21C, a sterile adapter 2100 may include a plate 2110 that has a tool side face configured to mate with a 2150 surgical tool. Plate 2110 may include one or more alignment features to facilitate the coupling and engagement of the surgical tool 2150. For example, as shown in Figure 21 A, plate 2110 may include a female guide 2114 (for example, one or more pairs longitudinal rail) configured to engage a 2156 male guide (Figure 21B) (for example, a longitudinally directed projection) or other guide feature on the 2150 surgical tool to help center the 2150 surgical tool as it is accommodated on the 2100 sterile adapter, as shown in Figure 21C. As shown in Figure 2B, a front end of the male guide 2156 can be tapered to facilitate progressive centering or alignment with the female guide 2114, as the surgical tool 2150 is attached to the sterile adapter 2100. Additionally or alternatively, the plate 2110 can include an outwardly extending male feature and the surgical tool can include a female guide configured to receive the male guide on plate 2110. As another example, as shown in Figure 21 A, plate 2110 can include one or more magnets 2112 in the side of the tool that is configured to magnetically attract a magnetic component 2156 on the surgical tool 2150. For example, the
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57/61 plate may include a magnet 2112 generally along a central line of projection 2156 of plate 2110 (Figure 21B) that is configured to attract and thus centralize a magnetic component centrally positioned on the surgical tool 2150 (for example, the 2156 male guide, which may include a ferromagnetic material) or other magnet component coupled to a center line of the 2150 surgical tool.
[00106] As shown in Figures 22A and 22B, the components of the magnetic and / or ferromagnetic material can additionally be included in one or more output drivers 2142 of the tool driver 2140, in one or more rotary couplers 2130 in the tool driver 2100 , and / or one or more inlet drivers 2152 on the surgical tool 2150, including a suitable combination of magnetically attractive and / or magnetically repellent materials or components to encourage self-alignment of the coupling components. For example, at least one output driver 2142 on tool driver 2140 can include one or more magnets 2144, and at least one corresponding coupler 2130 on sterile adapter 2100 can include one or more magnets 2132. Magnet 2144 can attract magnet 2132 , thus stimulating the self-alignment and engagement of the output driver 2142 and the coupler 2130. As another example, at least one input driver 2152 in the surgical tool 2150 may include one or more magnets 2153. The magnet 2132 in the adapter coupler sterile can attract magnet 2153 to the input trigger of the surgical tool, thus, similarly stimulating the self-alignment and engagement of coupler 2130 and input driver 2152.
[00107] In some variations, as shown in Figure 23A, the sterile adapter 2100 may include a displacement plate 2120 configured to move axially in the plane (eg, in a direction)
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58/61 along the direction of the tool driving axis of the surgical tool), where the displacement plate 2120 is configured to selectively allow the extension and retraction of the rotating couplers 2130 on the sterile adapter. For example, displacement plate 2120 can include slots that are configured to allow translation of displacement plate 2120 around outlet drivers 2120. In addition, each slot can have a raised edge that is engaged with a corresponding outlet driver 2130, where the raised edge can be sloped or tilted from one end of the slot to the other to selectively allow extension and retraction of the 2130 couplers on the sterile adapter. For example, in a retracted coupler position shown in Figure 23A, the 2130 couplers can be engaged with a higher point on the edge of the raised slot, which forces the 2130 couplers to withdraw towards the tool driver side of the sterile barrier (and away from the tool driver). For example, as shown in Figure 23A, the retracted couplers 2130 can be substantially flush with one side of the sterile adapter tool 2100. In an extended coupler position shown in Figure 23B, couplers 2130 can be engaged with a lower point on the edge the high slot, which allows the 2130 couplers (which can be pushed out due to spring and / or magnet actuation, etc.) to extend outward beyond the tool side of the sterile adapter.
[00108] Similar to at least some of the variations described above, the displacement of the plate 2120 between the positions retracted couplers and extended couplers can be triggered by engaging and / or disengaging the surgical tool 2150 from the sterile adapter 2100. For example, as shown in In Figure 23C, the surgical tool 2150 may include a 2160-confi tool plate
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59/61 secured to move up and down on one side facing the tool adapter. The tool plate 2160 can include a slot around each input driver 2152 to allow the tool plate 2160 to move without interfering with the input drivers 2152. The tool plate 2160 travel can be controlled, for example , through a connection inside the tool with the movable side handles 2162, which can be configured to be held and operated by a user. For example, side handles 2162 can slide into a groove on the surgical tool 2150, and may include frictional features such as a textured surface (for example, finger retaining ribs or contours) and / or a material with a high coefficient of friction (e.g. silicone). In addition or alternatively, the displacement of the tool plate 2160 can be controlled by a lock, lever, button, rotating wheel or any suitable mechanism.
[00109] The tool plate 2160 may additionally include the drive features of the displacement plate 2163 (for example, a cutout in the longitudinal ribs). In addition, as shown in Figure 23B, the displacement plate 2120 can include one or more extensions 2122 that extend through the openings of the sterile adapter plate 2100 to one side of the tool of the sterile adapter plate 2100. The process of fixing the surgical tool 2150 to the 2100 sterile adapter can cause the tool plate 2160 to move downwards. When the tool plate 2160 is moved downwards from the position shown in Figure 23C, the drive features of the displacement plate 2163 can engage the extensions 2122 and cause the displacement plate 2120 to shift from the retracted couplers position, shown in Figures 23A and 23B, for the extended couplers position, show
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60/61 as in Figures 24A and 24B. In some variations, the 2160 tool plate may include one or more 2164 springs or other suitable tilt features (for example, spring bundle) that are configured to tilt the 2150 tool toward engagement with the sterile adapter. When the 2130 coupling discs are extended in this way, they can be configured to pivotally align with and engage with the surgical driver's 2152 input drivers.
[00110] To decouple the surgical tool 2150 from the sterile adapter 2100, a reverse process can be applied. For example, the side handles 2162 of the tool 2150 can be actuated upwards, thus causing the tool plate 2160 to move upwards. When the tool plate 2160 is moved upward from the position shown in Figure 24C, the drive features of the displacement plate 2163 can engage the extensions 2122 and transpose the tilt force provided by the springs 2164 to make the plate displacement 2120 changes from the extended couplers position, shown in Figures 24A and 2B, to the retracted couplers position, shown in Figures 23A and 23B. When the coupling discs 2130 are retracted in this manner, they are disengaged from the 2152 input actuators of the surgical tool, thus allowing decoupling of the surgical tool 2150 from the sterile adapter 2100.
[00111] The aforementioned description, for the purpose of explanation, used a specific nomenclature to provide a complete understanding of the invention. However, it will be evident to the person skilled in the art that specific details are not necessary in order to practice the invention. Accordingly, the aforementioned descriptions of specific embodiments of the invention are presented for purposes of illustration and description. They are not intended to
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61/61 be exhaustive or limit the invention to the precise forms disclosed; obviously, many modifications and variations are possible in view of the above teachings. The modalities were chosen and described to better explain the principles of the invention and its practical applications and, thus, enable others skilled in the art to better use the invention and the various modalities with various modifications, as appropriate to the specific use contemplated. The following claims and equivalents are intended to define the scope of the invention.

权利要求:
Claims (15)
[1]
1. Sterile adapter for use in a robotic surgical system, characterized by the fact that it comprises:
a structure comprising:
a body configured to be interposed between a tool driver and a surgical tool, wherein the body comprises a first end and a second end opposite the first end;
an engagement feature arranged at the first end of the body to engage a first portion of the surgical tool that projects the body; and a platform bezel projecting from the second end of the body to receive a second portion of the surgical tool.
[2]
2. Sterile adapter, according to claim 1, characterized by the fact that the platform frame is projected in a generally perpendicular way from the second end of the body.
[3]
3. Sterile adapter, according to claim 1, characterized in that it additionally comprises a set of plates, in which the structure defines a generally flat opening and the set of plates is movable within the opening.
[4]
4. Sterile adapter according to claim 3, characterized in that it additionally comprises at least one rotating coupler supported by the plate set and configured to transmit torque from an output driver of the tool driver to an input driver of the surgical tool.
[5]
5. Sterile adapter, according to claim 4, characterized in that the coupler comprises a first face that has a first coupling feature configured to engage the action
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2/3 output driver of the tool driver, and the coupler additionally comprises a second face that has a second latching feature configured to engage the input driver of the surgical tool.
[6]
6. Sterile adapter according to claim 1, characterized in that it additionally comprises a selectively operable movable locking member between an engaged position, in which the locking member secures a frame coupling to the tool driver, and a disengaged position , in which the locking member facilitates decoupling of the structure from the tool driver.
[7]
7. Sterile adapter, according to claim 1, characterized in that the sterile adapter is configured to be coupled to a sterile trim.
[8]
8. Sterile barrier for use in a robotic surgical system, characterized by the fact that it comprises:
a sterile adapter comprising a structure configured to be interposed between a tool driver and a surgical tool, the structure having a structure perimeter and a first peripheral projection integrally formed with the structure extending laterally around at least a portion of the structure perimeter; and a sterile trim coupled to the first peripheral projection of the sterile adapter.
[9]
9. Sterile barrier, according to claim 8, characterized in that the structure includes a first material and the first peripheral projection includes a second material different from the first material.
[10]
10. Sterile barrier, according to claim 9, characterized by the fact that the first material is more rigid than the second
Petition 870190047448, of 05/21/2019, p. 121/141
3/3 material, and the second material comprises a flexible elastomeric material.
[11]
11. Sterile barrier, according to claim 8, characterized in that the first peripheral projection comprises an external flange that extends laterally around the perimeter of the structure.
[12]
12. Sterile barrier, according to claim 8, characterized in that the first peripheral projection is molded by co-injection with the structure.
[13]
13. Sterile barrier, according to claim 8, characterized in that the sterile trim is thermally connected to the first peripheral projection.
[14]
Sterile barrier according to claim 8, characterized in that it additionally comprises a second layered peripheral projection with the first peripheral projection.
[15]
15. Sterile barrier, according to claim 14, characterized by the fact that the sterile trim is arranged between the first peripheral projection and the second peripheral projection.

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WO2021105997A1|2019-11-28|2021-06-03|Microbot Medical Ltd.|Modular robotic system for driving movement of surgical tools|

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WO2021124572A1|2019-12-20|2021-06-24|リバーフィールド株式会社|Medical robot, surgical instrument, and mounting part|

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WO2021137107A1|2019-12-31|2021-07-08|Auris Health, Inc.|Tool detection system|

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CN111134740B|2020-01-07|2022-02-22|深圳市精锋医疗科技股份有限公司|Method for connecting surgical instrument and driving device, slave operation device, and surgical robot|

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US20210251720A1|2020-02-17|2021-08-19|Verb Surgical Inc.|Method and system for data exchange with robotic surgical tools using near field communicaiton |

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US20210315646A1|2020-04-08|2021-10-14|DePuy Synthes Products, Inc.|Surgical robotic systems including a sterile connector and related methods|

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GB2596647A|2020-07-02|2022-01-05|Prec Robotics Limited|A barrier|

法律状态:
2022-02-15| B06W| Patent application suspended after preliminary examination (for patents with searches from other patent authorities) chapter 6.23 patent gazette]|

优先权:

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申请号 | 申请日 | 专利标题

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US201662436965P| true| 2016-12-20|2016-12-20|

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US201662436981P| true| 2016-12-20|2016-12-20|

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US201662436957P| true| 2016-12-20|2016-12-20|

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US201662436974P| true| 2016-12-20|2016-12-20|

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PCT/US2017/067706|WO2018119136A1|2016-12-20|2017-12-20|Sterile adapters for use in a robotic surgical system|

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