Abstract:
An apparatus for cleaning robotic surgical instruments includes a tank having cleaning fluid there within and having a source of ultrasonic waved coupled thereto. A pump draws cleaning fluid through a tool-end cleaning chamber through a plurality of intake holes that are formed in the tool-end cleaning chamber at an angle of from 5 degrees to 85 degrees with respect to a side surface of the tool-end cleaning chamber, thereby creating turbulence and flow around an end of a robotic surgical instrument that is positioned in the tool-end cleaning chamber. Cleaning of the control box of the robotic surgical instrument is performed through suction of the cleaning fluid through the control box at the same time.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    This application is a continuation of U.S. patent application Ser. No. 14/268,121, filed May 2, 2014, the disclosure of which is hereby incorporated by reference. 
     
    
     FIELD 
       [0002]    This invention relates to the field of cleaning robotic surgical instruments after use in surgery, and in particular to an adaptation of a suction apparatus system that makes it possible to individually clean both the distal and proximal segmented areas of a robotic surgical instrument at the same time, while submerged in an ultrasonic cleaner. 
       BACKGROUND 
       [0003]    Robotic and other laparoscopic type surgical instruments have been in use for over a decade. In general, one or more small incisions are made in the patient and an operating device, such as a scope, or other instrument, is fed through the incision(s), until the surgical device(s) and/or instrument(s) reaches the site of the operation. The inserted portions of the robotic surgical instruments are typically tubular in shape. In some examples, the robotic or laparoscopic instrument is a scalpel, scissors, or other cutting device for removal or repair of diseased or malfunctioning tissue. Advances in surgical systems and surgical instruments have greatly reduced operation times as well as recovery times; such as the removal of a gallbladder, etc. 
         [0004]    U.S. Pat. No. 5,630,436 (hereafter &#39;436) describes one method of cleaning that has effectively cleaned the interiors and exteriors of channeled tubular surgical instruments, such as orthoscopic/laparoscopic/endoscopic/and bone reamers. The &#39;436 patent utilizes ultrasonic transducers affixed to the bottom of an ultrasonic tank that has been filled with cleaning solution, wherein the ultrasonic waves induce the separation of debris from the soiled instrument(s) placed in the ultrasonic bath. Further, in &#39;436, the ultrasonic tank is attached to an independent suction apparatus that works simultaneously to suction out the loosened debris from the interior and tool end of a channeled tubular surgical instrument while it is being cleaned in the ultrasonic bath. More recently, this is accomplished by inserting just the distal tool end of the channeled tubular surgical instrument through a hole in the capped, individually dedicated, inline maximizing suction cleaning chamber, inline filter, inline pump, and inline fluid return tube that returns the filtered ultrasonic tank cleaning solution back to the ultrasonic bath wherein the attached channeled tubular surgical instrument is laying on the bottom of the fluid filled activated ultrasonic tank. The current configuration of the &#39;436 can individually clean up to six channeled tubular surgical instruments at the same time using this well established cleaning system. 
         [0005]    The combined surgical instrument cleaning methods of &#39;436 have been used successfully in cleaning many types of flow through channeled tubular surgical instruments. However, this singular hookup method for cleaning channeled tubular surgical instruments in the &#39;436 is incapable of adequately cleaning Robotic tubular surgical instruments, such as the da Vinci® robotic surgical instruments manufactured by Intuitive Surgical, Inc., because one or more tight seals have been placed as a barrier between the distal tool end and the proximal shaft/control box end of the channeled areas within the robotic instrument in an effort to curtail the amount of bio burden at the tool end from migrating up into the segmented shaft/control box end; which reduces but does not totally prevent bio burden from migrating into the segmented proximal end of the robotic instrument. 
         [0006]    The typical institutional practice for cleaning the distal tool end of a robotic surgical instrument is to scrub it by hand; which is time consuming, tedious, potentially dangerous, and can lead to liability and workman&#39;s compensation issues. 
         [0007]    What is needed is a safer more cost effective automated way to clean both the distal and the proximal segmented areas of robotic surgical instruments. 
       SUMMARY 
       [0008]    In one embodiment, an apparatus for cleaning robotic surgical instruments is disclosed. The apparatus includes a tank having interfaced thereto a transducer that emits ultrasonic waves and having cleaning fluid within the tank. A pump is provided as well as a tool-end cleaning chamber. The tool-end cleaning chamber is fluidly interfaced to the pump through a suction attachment port on one side of a body of the tool-end cleaning chamber. The tool-end cleaning chamber fills with the cleaning fluid and as the pump pulls the cleaning fluid from within the tool-end cleaning chamber, the cleaning fluid is drawn from the tank into the tool-end cleaning chamber through a plurality of intake holes. The intake holes formed in body of the tool-end cleaning chamber at an angle of between 5 degrees and 85 degrees with respect to a surface of the body of the tool-end cleaning chamber, thereby creating turbulence for cleaning a tool-end of a robotic surgical instrument that has been inserted into the tool-end cleaning chamber and whereas the ultrasonic waves dislodge debris from the tool-end of the robotic surgical instrument. 
         [0009]    In another embodiment, an apparatus for cleaning robotic surgical instruments is disclosed including a tank with cleaning fluid within the tank, and a pump. A tool-end cleaning chamber is submerged within the tank and is fluidly interfaced to the pump through a suction attachment port on one side of a body of the tool-end cleaning chamber. The tool-end cleaning chamber is filled with the cleaning fluid, whereas, cleaning fluid is drawn into the tool-end cleaning chamber by the pump through a plurality of intake holes. The intake holes formed at an angle of from 5 degrees to 85 degrees with respect to the body of the tool-end cleaning chamber, thereby creating a flow of the cleaning fluid across a tool-end of a robotic surgical instrument inserted into the tool-end cleaning chamber. An ultrasonic generator is interfaced to the tank such that ultrasonic waves from the ultrasonic generator dislodge debris from the tool end of the robotic surgical instrument inserted into the tool-end cleaning chamber. A second pump is fluidly interfaced to a first orifice of a control box of the robotic surgical instrument such that as the second pump operates, the cleaning fluid is drawn into the robotic surgical instrument through a second orifice of the control box, the cleaning fluid flows through the control box, the cleaning fluid circulates through a shaft of the robotic surgical instrument, and the cleaning fluid exits the first orifice of the control box to the second pump. 
         [0010]    In another embodiment, apparatus for cleaning robotic surgical instruments is disclosed including a tank having cleaning fluid there within and a pump A tool-end cleaning chamber is fluidly interfaced to the pump through a suction attachment port on one side of a body of the tool-end cleaning chamber. The tool-end cleaning chamber submerged in the cleaning fluid and the tool-end cleaning chamber is filled with the cleaning fluid. Cleaning fluid is drawn into the tool-end cleaning chamber by the pump through a plurality of intake holes that are formed at an angle of from 5 degrees to 85 degrees with respect to the body of the tool-end cleaning chamber, thereby creating a flow of the cleaning fluid across a tool-end of a robotic surgical instrument inserted into the tool-end cleaning chamber. An ultrasonic generator interfaced to the tank such that ultrasonic waves from the ultrasonic generator dislodge debris from the tool end of the robotic surgical instrument inserted into the tool-end cleaning chamber. The pump is also fluidly interfaced to a first orifice of a control box of the robotic surgical instrument such that as the pump operates, the cleaning fluid is drawn into the robotic surgical instrument through a second orifice of the control box, the cleaning fluid flows through the control box, the cleaning fluid circulates through a shaft of the robotic surgical instrument, and the cleaning fluid exits the first orifice of the control box to the pump. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0011]    The invention can be best understood by those having ordinary skill in the art by reference to the following detailed description when considered in conjunction with the accompanying drawings in which: 
           [0012]      FIG. 1  illustrates a cut-away view of a tool-end cleaning chamber of a system for cleaning robotic surgical instruments. 
           [0013]      FIG. 2  illustrates a cut-away view of a control box/shaft-end cleaning chamber of the system for cleaning robotic surgical instruments. 
           [0014]      FIG. 3  illustrates a plan view of the system for cleaning robotic surgical instruments. 
           [0015]      FIG. 4  illustrates a cut-away view of a tool-end cleaning chamber of the system for cleaning robotic surgical instruments having there within a tool-end of a robotic surgical instrument. 
           [0016]      FIG. 5  illustrates a cut-away view of an alternate tool-end cleaning chamber of the system for cleaning robotic surgical instruments having there within a tool-end of a robotic surgical instrument. 
       
    
    
     DETAILED DESCRIPTION 
       [0017]    Reference will now be made in detail to the presently preferred embodiments of the invention, examples of which are illustrated in the accompanying drawings. Throughout the following detailed description, the same reference numerals refer to the same elements in all figures. 
         [0018]    The system for cleaning robotic surgical instruments is shown and described in use with one specific soiled instrument, e.g., as shown a da Vinci® robotic surgical instrument. This is one of the many different soiled instruments that system for cleaning robotic surgical instruments will clean and is shown as an example of such, not to be taken as limiting in any way. In general, such instruments are anticipated to be of generally elongated shape, though not required to be such. Also, such instruments are also anticipated to have tubular shafts with a control portion at one end of the shaft and a tool-end portion at an opposing end of the shaft, but again, there is no specific limitation on the overall shape, geometry, or size of the instruments to be cleaned. 
         [0019]    The system for cleaning robotic surgical instruments operates on four base principles: immersing the soiled instrument in a cleaning solution; dislodging debris from the soiled instruments using ultrasonic waves; pumping fluid away from the instrument so that dislodged debris will flow out of the instrument and be captured in filters; and fluid jet cleaning of the tool-end of the instrument; as will be shown in the description related to the drawings. By pumping fluid away from the both ends to the robotic surgical instruments, any dislodged debris is pulled out of the robotic surgical instruments and trapped in a filter, rather than being pushed back into the robotic surgical instruments where is may get further lodged and, hence, not cleaned sufficiently. 
         [0020]    Referring to  FIG. 1 , a cut-away view of a tool-end cleaning chamber  10  of a system for cleaning robotic surgical instruments  90 / 92 / 93 / 94 / 96 / 98 / 99  (see  FIGS. 1-4 ) is shown. The tool-end cleaning chamber  10  comprises a body  12  that has a hollow core  14  that is preferably of a diameter slightly larger than a diameter of the expected tool-end  93 / 94 , a suction attachment port  16 , and an open receptor end  20 . The tool-end cleaning chamber  10  is made of any suitable material such as a solid material that resists oxidation and accumulation of debris for example stainless steel or a hard plastic. The open end  20  of the tool-end cleaning chamber  10  engages with a flexible nipple  22  or cover  22 . The flexible nipple  22  has an orifice  24 , through which the tool-end  93 / 94  of a soiled surgical instrument is inserted, forming a seal around the shaft  92  of the robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99 . The tool-end  93 / 94  is the end which typically is inserted into the patient for cutting of tissue, etc., and the tool-end  93 / 94  typically acquires a large share of the body tissue and fluids during an operation. 
         [0021]    Note that many robotic surgical instruments  90 / 92 / 93 / 94 / 96 / 98 / 99  have a very effective seal  99 , through which it is difficult or impossible to flow materials through (e.g. between the tool-end  93 / 94  and the shaft  92 ) and, therefore, the tool-end  93 / 94  needs to be cleaned separately from the shaft  92  and the control box/shaft-end  90 / 92 / 96 / 98 , which is cleaned from ports  96 / 98  on the control box  90  as described with  FIG. 2 . 
         [0022]    The tool-end cleaning chamber  10  has a plurality of intake holes  18  are formed in the body  12 . The intake holes  18  are sized and spaced in such a way that, as negative pressure (suction) is applied to the suction port  16  through suction tubes  30 / 34  and, preferably, a filter  32 , cleaning fluids  104  from the ultrasonic immersion tank  100  (see  FIG. 3 ), flow through the intake holes  18  and into the hollow core  14 , creating turbulence that, in conjunction with or separate from the ultrasonic waves, dislodges debris from the tool-end  93 / 94 . As debris is dislodged, the suction pulls the debris out the suction port  16  where it flows into the filter  32  and is trapped in the filter&#39;s media. 
         [0023]    By keeping the hollow core  14  as narrow as to provide enough clearance for the tool-end  93 / 94  to fit, the turbulence and flow created by the cleaning fluid  104  being drawn in through the intake holes  18  concentrates in areas of the tool-end  93 / 94  that is mostly soiled. Although the intake holes  18  are shown on one side of the body  12  and equally spaced, any configuration of intake holes  18  is anticipated to provide ample flow through the intake holes  18 , causing flow and turbulence which results in improved cleaning. 
         [0024]    Referring to  FIG. 2 , a cut-away view of a control-end cleaning chamber  40  of a system for cleaning robotic surgical instruments  90 / 92 / 93 / 94 / 96 / 98 / 99  is shown. Some systems for cleaning robotic surgical instruments  90 / 92 / 93 / 94 / 96 / 98 / 99  are equipped to clean other types of surgical instruments (not shown) that permit flow of fluids in one end and out the other, as described in U.S. Pat. No. 5,630,436. In such, one end of this type of surgical instrument (not shown) is inserted into a cleaning chamber  40  similar to that shown in  FIG. 2  and, as suction is drawn from the suction tube  60 , fluids flow in to this surgical instrument (not shown) from an end distal to the cleaning chamber  40 . Being that the seals on certain robotic surgical instruments  90 / 92 / 93 / 94 / 96 / 98 / 99  are very robust, this flow is not possible. Therefore, the control box  90  and shaft  92  need to be cleaned by flowing fluid through the control box  90  and shaft  92  from the control box  90 . 
         [0025]    In one embodiment, it is anticipated that the suction tube  60  is connected directly to an orifice  96  on the control box  90  of the robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99  by, for example, a male-male fitting  56  (not shown). 
         [0026]    In another embodiment, because other types of surgical instruments (not shown) are often cleaned using a control box/shaft-end cleaning chamber  40  similar to that shown in  FIG. 2 , the same control box/shaft-end cleaning chamber  40  is used. By using the same control box/shaft-end cleaning chamber  40 , little or less disassembly and reassembly is required when switching between cleaning of different surgical instruments. Therefore, it is preferred to attach the control box/shaft-end cleaning chamber  40  to the orifice  96  on the control box  90  of the robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99 . In such, the control box/shaft-end cleaning chamber  40  comprises a body  42  that has a hollow core  44 , a suction attachment port  46 , and an open receptor end  50 . The control box/shaft-end cleaning chamber  40  is also made of any suitable material such as stainless steel. The open end  50  of control-end cleaning chamber  40  engages with a second flexible nipple  52  (or cover). The second flexible nipple  52  has an orifice  54 , through which a first end of a male-male fitting  56  is inserted. An opposing end of the male-male fitting  56  interfaces with a port  96  on the control box  90  of the robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99 . 
         [0027]    As negative pressure (e.g. suction) is applied to the suction port  46  through suction tubes  60 / 64  and, preferably, a filter  62 , cleaning fluids  104  from the ultrasonic immersion tank  100  (see  FIG. 3 ), flow into, for example, an orifice  98  of the control box  90  of the robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99 , through inner channels and shaft  92  of the robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99 , out the orifice  96  of the control box  90 , through the male-male fitting  56  and into the hollow core  44 . As ultrasonic waves dislodge debris from the internal channels (e.g. of the shaft  92 ) of the robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99 , the negative pressure (suction) pulls the debris out the suction port  46  where it flows into the filter  62  where the debris is trapped in the filter&#39;s media. 
         [0028]    Referring to  FIG. 3 , a plan view of the system for cleaning robotic surgical instruments  90 / 92 / 93 / 94 / 96 / 98 / 99  is shown. The tool-end  93 / 94  of a soiled robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99  is shown inserted into the tool-end cleaning chamber  10 , passing through the orifice  24  in the flexible nipple  22 . As suction (negative pressure) is pulled from the suction attachment port  16  of the tool-end cleaning chamber  10 , cleaning fluid  104  flows into the hollow core  14  of the tool-end cleaning chamber  10  through the plurality of intake holes  18 , creating turbulence within the hollow core  14 , thereby dislodging debris from the tool-end  93 / 94 , which debris flows along the path of the suction through the suction tube  30  and is trapped within the optional filter  32 . The filter is operatively connected to a source of negative pressure (suction) such as a pump  84 , by a continuing tube  34 . As the pump operates and receives fluid from the filter  32  and tube  34 , the fluid is recirculated into the ultrasonic immersion tank  100  through an exit tube  86 . 
         [0029]    The male-male fitting  56  is shown interfacing between the orifice of the  54  of the second flexible nipple  52  and the orifice  96  on the control box/shaft-end  90  of the robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99 . As suction is pulled from the suction port  46  by a second pump  80  (or in some embodiment, the same pump  84 ), debris from within the soiled robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99  is pulled through suction tube  60  and is captured by a filter  62 . After passing through the pump  80 , the fluid is recirculated back into the ultrasonic immersion tank  100  through an exit tube  82 . 
         [0030]    During cleaning, it is preferred that the entire robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99  is submerged within the cleaning fluid  104  of the ultrasonic immersion tank  100 . In this, ultrasonic waves from the ultrasonic emitting device  102  will vibrate debris from the surfaces of the robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99 . 
         [0031]    Referring to  FIG. 4 , a cut-away view of a tool-end cleaning chamber  10  of the system for cleaning robotic surgical instruments  90 / 92 / 93 / 94 / 96 / 98 / 99  having there within placed an tool-end of a robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99  is shown. The tight fit between the orifice  24  of the flexible nipple  22  attached to the opening  20  of the tool-end cleaning chamber  10  and the extended shaft  92  of the robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99  is visible in  FIG. 4 . As negative pressure (suction) is applied to the suction port  16  through suction tubes  30 / 34  and the filter  32 , cleaning fluids  104  from the ultrasonic immersion tank  100 , flow into the hollow core  14  through the intake holes  18  and into the hollow core  14 , forming turbulence (shown as looping arrows). As the ultrasonic waves and the turbulent flow dislodge debris from the tool-end  93 / 94  of the robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99 , the suction pulls the debris out the suction port  16  where the debris flows into and is trapped in the filter  32 . The remaining cleaning fluid  104  flows through the pump  84  and is returned back into the ultrasonic immersion tank  100 . 
         [0032]    Referring to  FIG. 5 , a cut-away view of an alternate tool-end cleaning chamber  10  of the system for cleaning robotic surgical instruments  90 / 92 / 93 / 94 / 96 / 98 / 99  having there within placed an tool-end of a robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99  is shown. The tight fit between the orifice  24  of the flexible nipple  22  attached to the opening  20  of the tool-end cleaning chamber  10  and the extended shaft  92  of the robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99  is visible in  FIG. 5 . As negative pressure (suction) is applied to the suction port  16  through suction tubes  30 / 34  and the filter  32 , cleaning fluids  104  from the ultrasonic immersion tank  100 , flow into the hollow core  14  through the intake holes  18  and into the hollow core  14 , forming turbulence (shown as looping arrows). As the ultrasonic waves and the turbulent flow dislodge debris from the tool-end  93 / 94  of the robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99 , the suction pulls the debris out the suction port  16  where the debris flows into and is trapped in the filter  32 . The remaining cleaning fluid  104  flows through the pump  84  and is returned back into the ultrasonic immersion tank  100 . In this alternate design, the intake holes  18  are formed at an angle with respect to the surface of the body  12  of the tool end cleaning chamber  10 . As suction is drawn out of the suction port  16 , fluid enters the angled intake holes  18  that are preferably aimed at the portion of the tool-end  93 / 94  of the robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99  that is likely to be the most soiled. The angle of the intake holes  18  increases turbulence within the tool-end cleaning chamber  10 , thereby improving dislocation and removal of debris from the tool-end  93 / 94  of the robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99 . Although any angle with respect to the surface of the body  12  of the tool end cleaning chamber  10  is anticipated, a 5 degree to 85 degree angle with respect to the body  12  of the tool end cleaning chamber  10  is preferred, more specifically, a 35 degree to 45 degree angle is preferred. 
         [0033]    It is anticipated that any number of pumps  80 / 84  are used, including one pump  80 . Likewise, it is anticipated that any number of filters  32 / 62  are used, including one filter  32 . It is also anticipated that multiple robotic surgical instrument  90 / 92 / 93 / 94 / 96 / 98 / 99  be cleaned simultaneously within the same ultrasonic immersion tank  100 , providing multiple sets of tool-end cleaning chambers  10  and control box/shaft-end cleaning chambers  40 , with as many pumps  80 / 84  and filters  32 / 62  as needed. 
         [0034]    Equivalent elements can be substituted for the ones set forth above such that they perform in substantially the same manner in substantially the same way for achieving substantially the same result. 
         [0035]    It is believed that the system and method as described and many of its attendant advantages will be understood by the foregoing description. It is also believed that it will be apparent that various changes may be made in the form, construction and arrangement of the components thereof without departing from the scope and spirit of the invention or without sacrificing all of its material advantages. The form herein before described being merely for example and showing explanatory embodiment thereof. It is the intention of the following claims to encompass and include such changes.