Abstract:
A tray assembly includes an articulatable arm assembly coupled with a tray and selectively held in place by a locking mechanism (e.g., a locking gas spring). A release mechanism coupled with the tray selectively activates and deactivates the gas shock mechanism and is coaxial with and free rotating with respect to an axis of rotation of the tray. The tray may rotate between a horizontal position and a stored position substantially orthogonal to the horizontal position. The arm assembly may include at least one frictional hinge comprising a tapered pin, a tapered bushing in rotational frictional contact with the tapered pin, and an adjustment mechanism coupled to the tapered pin to provide adjustable contact force between the tapered pin and the tapered bushing.

Description:
TECHNICAL FIELD 
       [0001]    The present invention generally relates to surgical tray systems, and more particularly relates to articulatable surgical tray assemblies of the type used in connection with portable surgical consoles. 
       BACKGROUND 
       [0002]    Surgical consoles generally include, among other things, a tray configured to articulate with respect to a console. One or more interconnected arms coupled to the tray are selectively secured in place via a locking mechanism, such as a gas spring or the like. During use, the tray is configured to remain horizontal, and the operator manually engages or disengages the locking mechanism to reposition the arms and tray in the desired position. 
         [0003]    Known surgical consoles are unsatisfactory in a number of respects. For example, the use of gas springs typically requires incorporating some form of release mechanism, such as a release cable, between the tray and the gas spring. Such release cables often restrict the movement of the tray and arms, as they cannot generally accommodate a wide range of tray positions, and thus can easily become tangled in the arms and related interconnects. 
         [0004]    Furthermore, as conventional tray systems maintain the tray in a generally horizontal position, the storage and transport of such surgical consoles can be difficult, as the tray extends a significant distance outward from the console in an unlocked position. This results in a non-compact and difficult-to-transport configuration. 
         [0005]    Moreover, the various hinges and interconnects used in conventional surgical console arm assemblies tend to allow the tray to swing outward with very little resistance, and are often ineffective in keeping the tray in a specific desired location and orientation. In addition, such conventional hinges are subject to hysteresis. That is, they tend to exhibit a lag in response to applied force. 
         [0006]    Accordingly, it is desirable to provide articulatable surgical tray assemblies that allow an increased range of motion, can be more easily stored and transported, have improved hinge mechanisms, and incorporate cable release mechanisms that allow for a greater range of tray rotation. Other desirable features and characteristics of the present invention will become apparent from the subsequent detailed description and the appended claims, taken in conjunction with the accompanying drawings and the foregoing technical field and background. 
       BRIEF SUMMARY 
       [0007]    In accordance with one embodiment of the present invention, a tray assembly includes an articulatable arm assembly coupled with a tray and selectively held in place by a locking mechanism (e.g., a locking gas spring). A release mechanism coupled with the tray selectively activates and deactivates the gas shock mechanism and is coaxial with and free rotating with respect to an axis of rotation of the tray. 
         [0008]    In accordance with a further embodiment of the present invention, a tray assembly includes an articulatable arm assembly coupled with a tray, wherein the tray is selectively latched to the articulatable arm assembly such that the tray may rotate between a horizontal position and a stored position substantially orthogonal to the horizontal position. 
         [0009]    In accordance with a further embodiment of the present invention, a tray assembly includes an articulatable arm assembly coupled with a tray, wherein the arm assembly includes at least one frictional hinge comprising a tapered pin, a tapered bushing in rotational frictional contact with the tapered pin, and an adjustment mechanism coupled with the tapered pin to provide adjustable contact force between the tapered pin and the tapered bushing. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    A more complete understanding of the present invention may be derived by referring to the detailed description and claims when considered in conjunction with the following figures, wherein like reference numbers refer to similar elements throughout the figures. 
           [0011]      FIG. 1  is an overview of a surgical console system useful in describing the present invention; 
           [0012]      FIGS. 2-5  present various isometric views of a tray and arm assembly in accordance with one embodiment; 
           [0013]      FIG. 6  is an isometric bottom view of various components of an exemplary tray; 
           [0014]      FIG. 7  is a top view of the end of the outer arm assembly; 
           [0015]      FIG. 8  is a cross-section through the top view shown in  FIG. 7 ; 
           [0016]      FIG. 9  is a top view of the inner arm and associated mount; and 
           [0017]      FIG. 10  is a cross-section through the top view shown in  FIG. 10 . 
       
    
    
     DETAILED DESCRIPTION 
       [0018]    The following detailed description is merely illustrative in nature and is not intended to limit the invention or the application and uses of the invention. Furthermore, there is no intention to be bound by any expressed or implied theory presented in the preceding technical field, background, brief summary or the following detailed description. The invention may be described herein in terms of functional and/or logical block components and various processing steps. For the purposes of conciseness, conventional techniques and systems related to surgical tray systems, hydraulics, friction hinges and the like are not and need not be described in detail herein. 
         [0019]    Referring now to  FIG. 1 , a surgical console system  100  in accordance with one embodiment of the present invention generally includes a surgical console  300  having a tray  45  coupled with a console body (or simply “body”)  302  via a tray arm  200  having any number of articulating interconnects and linkages as described in further detail below. In this way, tray  45  may be selectively positioned and oriented in space. 
         [0020]    A typical surgical console  300  may have a variety of shapes and will generally include a number of subcomponents, drawers, and the like, but in general often contains one or more displays or monitors  304  that generally define a “front”—i.e., a surface or combination of surfaces that are facing an operator in a typical viewing orientation during conventional use. Thus, in the illustrated embodiment, tray arm  200  is coupled with body  302  via a mount  56  that is secured to what would generally be considered the “front” of surgical console  300 . Note, however, that the present invention is not limited to any particular size, shape, or configuration of surgical console system, and that the particular system  100  illustrated in  FIG. 1  is merely one example useful in describing the present invention. 
         [0021]    Typically, tray  45  remains in a horizontal orientation (generally planar and parallel to the floor) to hold various workpieces and tools during use. In accordance with one aspect, however, tray arm  200  and its associated components are configured such that tray  45  may be rotated and folded substantially flat against body  302  of console  300 , while tray arm  200  collapses in a compact fashion to facilitate this configuration. A handle or other actuator preferably incorporated into tray  45  is engaged by the operator to release a locking mechanism and to reposition the various illustrated components. 
         [0022]    More particularly, unlike prior art systems, tray  45  may be positioned and latched adjacent to body  302  (e.g., the front of body  302 ) such that tray axis  101  (an axis coplanar with the plane of tray  45  and, in this case, its minor axis) is substantially parallel to the console axis  102 —i.e., an axis generally perpendicular to the floor or surface upon which it rests. Such a configuration is advantageous for, inter alia, transport and storage of system  100 . 
         [0023]    At the same time, tray arm  200  provides tray  45  a wide range of motion such that it may be placed on nearly all sides of body  302  during use (e.g., with reference to  FIG. 1 , tray  45  extends both to the left and right of the front surface generally defined by monitor  304 ). 
         [0024]      FIGS. 2-5  provide helpful illustrations of an exemplary tray arm  200  in various configurations and from a variety of viewpoints. As shown, tray arm  200  generally includes two assemblies: an inner arm assembly  202  (e.g., the arm assembly more closely linked to the console body) and outer arm assembly  203  (the arm assembly linked to tray  45 ). Inner arm assembly  202  is linked to the console body (not illustrated) via a suitable mount  56 . Furthermore, each of the various linkages are coupled via respective interconnects  210 ,  212 , and  214 , which may have a variety of degrees-of-freedom to effect proper movement of tray  45 . Arm assemblies  202  and  203  may have any suitable shape, and may be accompanied by various other linkages and other mechanical components known in the art. 
         [0025]      FIGS. 2-4  depict movement of tray arm  200  and tray  45  from an extended position where tray  45  is placed to the left of mount  56  (as viewed in  FIG. 2 ), to a position where inner arm assembly  202  and outer arm assembly  203  are at approximately a 90 degree angle ( FIG. 3 ), to a fully collapsed position where inner arm and outer arm assemblies  202  and  203  are adjacent and oriented 180 degrees with respect to each other, while tray  45  is oriented such that the plane of tray  45  is oriented perpendicular to its typical horizontal orientation during use, allowing it to lie substantially flat vertically adjacent to the console body (not shown). In this position, a latching mechanism allows the tray to be released from its typical horizontal position for storage, where it may be secured by a secondary clip coupled with body  302 . 
         [0026]      FIG. 5  is an isometric underside view corresponding to the configuration illustrated in  FIG. 2 . As can be seen from this figure in conjunction with  FIGS. 2-4 , interconnect  210  between mount  56  and inner arm assembly  202  provides one degree of freedom (i.e., lateral rotation), and interconnect  212  provides two degrees of freedom (lateral rotation accompanied by rotation along an orthogonal axis). Interconnect  214  allows rotation around two axes as well as other features, described in detail below. 
         [0027]    A locking mechanism, such as a locking gas shock/spring (“shock”)  6 , is coupled between interconnects to lock the arm in place and thereby stabilize tray  45 , as is known in the art. Such locking gas springs (or “shocks”) allow selective locking of the spring in a desired linear position. The present invention is not limited to any particular type or configuration of locking mechanism. 
         [0028]    This wide range of motion depicted in the figures is accomplished, in part, through the use of a novel cable release scheme that allows for rotation of tray  45  without tangling the release cable as is typical in prior art systems. In one embodiment, for example, surgical tray  45  includes a handle or other actuator that comes into contact with a pin at the pivot of the tray  45 . When the handle is pulled, the pin pivots, causing a connected lever to be raised. The lever is mechanically coupled with the cable such that raising the lever causes the cable to be pulled tight, which releases a valve on the gas shock or otherwise disables the locking mechanism. This allows tray  45  to continue to rotate around the pivot at the interface of the outer arm and the tray. 
         [0029]    More particularly,  FIGS. 6-8  depict a release mechanism in accordance with an exemplary embodiment. As shown in  FIG. 6 , the underside of a subsystem within tray  45  generally includes a tray release handle (or simply “handle”)  66  coupled with tray bottom panel  68  via a spring mechanism  11 . Handle  66  is secured within handle guide  41  to constrain movement to spring-loaded translation with respect to panel  68 . Handle guide  41  is secured to a tray mount bracket  64 , and handle  66  is coupled with lift pin block  51  (which is secured via screws  29 ) as described below. A tray drape (e.g., wire drape)  42  may be secured to panel  68  via a wire form guide  38 , and a tray lock pin  40  is provided for latching during use. 
         [0030]      FIG. 7  is a top view of the end of outer arm  203  with the tray removed, and illustrates a cable lift housing  46 , pin dowel (or simply “pin”)  24 , and lift pin block  51 . As can be seen, lift pin block  51  allows pin  24  to move laterally within a corresponding slot. A cross-section (B-B) through these components is shown in  FIG. 8 . 
         [0031]    As shown in  FIG. 8 , a cable release  72  includes a wire  76  that terminates on one end in a ball or bead  75 . Wire  76  is threaded through cable lift block  48  such that bead  75  abuts a surface of cable lift block  48 , which is provided within a cable lift housing  46 . Pin dowel  24  abuts cable lift block  48 , which pivots on pin  25 . A screw or other stop mechanism  22  restricts rotation of block  48  due to tension applied by bead  75  and wire  76 . 
         [0032]    Wire  76  (and, in general, a portion of release cable  72 ) fits within a central bore within hub spindle bolt (or simply “bolt”  54 ), and extends out through a strain relief component  7 . A set screw  16  may be used to secure bolt  54 . A washer (e.g., thrust washer)  14 , a bearing  3 , and a second washer  18  are provided between the rotating components—i.e., swivel  57  and lift hub  58 . Thus, as spindle bolt  54  is coaxial with the axis of rotation of swivel  57  with respect to lift hub  58 , release cable  72  does not experience tangling during rotation, and therefore the tray (which is coupled with swivel  57  via pivot shaft  70 ) may be freely rotated 360 degrees. Lift hub  58  rotates with respect to the outer arm via pivot bolt  59 . 
         [0033]    A tray lock latch  44 , torsion spring  43 , screw  23  coupled with swivel  57  are used to latch to and position tray  45 . In general, this latch can be actuated manually to release tray  45  and allow for storage (e.g., the vertical position shown in  FIG. 4 ). That is, latch  44  selectively engages tray lock pin  40  ( FIG. 6 ) via torsion spring  43 . 
         [0034]    When tray release handle  66  is actuated (e.g., pulled toward the operator), it causes pin  24  to be rotated slightly (clockwise in  FIG. 8 ) causing the left side of the lever formed by block  48  to be raised. When thus actuated, bead  75  is similarly raised, causing movement of wire  76  within release cable  72 , which is coupled with a suitable power shock system (not shown). When block  48  is not raised (i.e., handle  66  is not being actuated), cable  72  is configured such that it is loose enough to allow for complete rotation of the tray. In this way, rotation of swivel  57  is not impeded by release cable  72 . 
         [0035]    In accordance with another aspect, tray arm  200  incorporates one or more frictional hinges that may be tightened to various degrees without incurring hysteresis in movement. For example,  FIG. 9  shows a top view of interconnect  210  between mount  56  and inner arm assembly  202 , while  FIG. 10  shows a relevant cross-section through this assembly. The frictional hinge illustrated in these figures may also be implemented in any of the other interconnects previously described. 
         [0036]    As illustrated, a pivot shaft (“tapered pin,” or “shaft”)  67  is coaxially inserted within a tapered pin seat (or “tapered bushing”)  53 , which may comprise any combination of materials sufficient to provide the desired level of friction to inhibit rotation of shaft  67  with respect to mount  56 . In one embodiment, pin seat  53  is a Delrin acetal bushing, and shaft  67  is a conventional stainless steel. 
         [0037]    An adjustment nut  36  coupled with one end of shaft  67  secures it to bottom  60  of inner arm  202 . The opposite side of shaft  67  seats within top  61  of inner arm  202 , and may be secured via one or more set screws  35 . A suitable washer  19  is positioned between the bottom  60  of inner arm  202  and inner mount  56 . 
         [0038]    When inner arm  202  rotates with respect to mount  56 , taper pin seat  53  and shaft  67  produce a frictional resistance force whose magnitude can be easily adjusted by tightening or loosening nut  36 . That is, tightening nut  36  increases the axial tensile force and consequently the frictional contact force between the two members. The use of a tapered contact area  902  in conjunction with this adjustment mechanism allows the hinge to be tightened without incurring the hysteresis experienced in prior art systems. The degree of taper (or bevel angle) as well as the diameter, size, and shape of the tapered region  902  may be selected to achieve the desired resistance. In one embodiment, for example, the bevel angle is between about 20 and 40 degrees. 
         [0039]    While at least one example embodiment has been presented in the foregoing detailed description, it should be appreciated that a vast number of variations exist. It should also be appreciated that the example embodiment or embodiments described herein are not intended to limit the scope, applicability, or configuration of the invention in any way. Rather, the foregoing detailed description will provide those skilled in the art with a convenient road map for implementing the described embodiment or embodiments. It should be understood that various changes can be made in the function and arrangement of elements without departing from the scope of the invention and the legal equivalents thereof.