Patent Publication Number: US-11382493-B2

Title: Multi-stage instrument connector

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This patent application is a continuation application of U.S. patent application Ser. No. 15/262,653, filed Sep. 12, 2016, which is the U.S. national phase of International Application No. PCT/US2015/020879 filed Mar. 17, 2015 which claims priority to U.S. Provisional Application No. 61/954,200, filed Mar. 17, 2014, entitled “MULTI-STAGE INSTRUMENT CONNECTOR” by Bruce M. Schena, the contents of which are incorporated herein by reference in their entirety and for all purposes. 
    
    
     FIELD 
     The present disclosure is directed to systems and methods for coupling surgical instruments to input/output sources, and more particularly to systems and methods for efficiently and reliably integrating making connections to surgical instruments. 
     BACKGROUND 
     Surgical instruments such as those used in minimally invasive medical procedures are intended to enhance the performance of such procedures and/or reduce the amount of tissue that is damaged, thereby reducing patient recovery time, discomfort, and deleterious side effects. Such instruments often require multiple input/output connections. For example, CCD endoscopes include connectors to for high-powered illumination sources and additional electrical connectors can increase setup time and potentially increase the chance of connector damage. 
     Accordingly, it is desirable to provide a surgical instrument that facilitates quick and reliable connections. 
     SUMMARY 
     By integrating a first transmission channel for a surgical instrument into a connection alignment feature, a connector structure can be implemented that sequentially aligns and engages a second transmission channel after the first transmission channel. 
    
    
     
       BRIEF DESCRIPTIONS OF THE DRAWINGS 
       Aspects of the present disclosure are best understood from the following detailed description when read with the accompanying figures. It is emphasized that, in accordance with the standard practice in the industry, various features are not drawn to scale. In fact, the dimensions of the various features may be arbitrarily increased or reduced for clarity of discussion. In addition, the present disclosure may repeat reference numerals and/or letters in the various examples. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. 
         FIG. 1  shows an exemplary medical system including a multi-mode integrated connector. 
         FIG. 2  shows an exemplary instrument connector incorporating multiple mode interfaces. 
         FIG. 3  shows an exemplary console connector incorporating multiple mode interfaces. 
         FIGS. 4A-4E  show an exemplary engagement operation for the instrument connector of  FIG. 2  and the console connector of  FIG. 3 . 
         FIGS. 5A-5C  show an exemplary engagement operation for an instrument connector and a console connector according to some embodiments. 
         FIGS. 6A-6B  show another exemplary engagement operation for the instrument connector of  FIG. 2  and the console connector of  FIG. 3 . 
         FIG. 7  shows an exemplary interaction between the instrument connector of  FIG. 2  and the console connector of  FIG. 3 . 
     
    
    
     DETAILED DESCRIPTION 
     In the following detailed description of the embodiments of the invention, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. However, it will be obvious to one skilled in the art that the embodiments of this disclosure may be practiced without these specific details. In other instances well known methods, procedures, components, and circuits have not been described in detail so as not to unnecessarily obscure aspects of the embodiments of the invention. 
     As used herein, “end effector” may refer generally to a functional end of a medical device. For instance, one example of an end effector is a connector at the end of a length of cable. Another example of an end effector is an image capture device located at a distal end of an endoscope. “End effector” can also refer to an actual working distal part that is manipulable by means of a wrist member for a medical function, e.g., for effecting a predetermined diagnosis or treatment of a tart tissue. For instance, some end effectors have a single working member such as an image capture device, a scalpel, a blade, or an electrode. Other end effectors have a pair or plurality of working members such as forceps, graspers, scissors, or clip appliers, for example. In certain embodiments, the disks or vertebrae are configured to have openings which collectively define a longitudinal lumen or space along the wrist, providing a conduit for any one of a number of alternative elements or instrumentalities associated with the operation of an end effector. Examples include conductors for electrically activated end effectors (e.g., electrosurgical electrodes; transducers, sensors, and the like); conduits for fluids, gases or solids (e.g., for suction, insufflation, irrigation, treatment fluids, accessory introduction, biopsy extraction and the like); mechanical elements for actuating moving and effector members (e.g., cables, flexible elements or articulated elements for operating grips, forceps, scissors); wave guides; sonic conduction elements; fiber optic elements; and the like. Such a longitudinal conduit may be provided with a liner, insulator or guide element such as an elastic polymer tube; spiral wire would tube or the like. 
     As used herein, the terms “surgical instrument”, “instrument”, “surgical tool”, or “tool” refer to a member having a working end which carries one or more end effectors to be introduced into a surgical site in a cavity of a patient, and is actuatable from outside the cavity to manipulate the end effector(s) for effecting a desired treatment or medical function of a target tissue in the surgical site. The instrument or tool typically includes a shaft carrying the end effector(s) at a distal end, and is preferably servomechanically actuated by a telesurgical system for performing functions such as holding or driving a needle, grasping a blood vessel, and dissecting tissue. 
     By integrating a first transmission channel for a surgical instrument into a connection alignment feature, a connector structure can be implemented that sequentially aligns and engages a second transmission channel after the first transmission channel. 
     Referring to  FIG. 1  of the drawings, a surgical system is generally indicated by the reference numeral  100 . Note that as used herein, “surgical” can refer to any medical procedure performed on a patient, including without limitation operative procedures (e.g., tissue extraction or manipulation), therapeutic procedures (e.g., medicament delivery), and diagnostic procedures (e.g., tissue examination or biopsy). As shown in  FIG. 1 , the surgical system  100  generally includes a control console  110  for operating a surgical instrument  140 . A user interface  120  allows a clinician to operate/monitor instrument  140  (e.g., via an optional display  130 ). Such operation/monitoring can be direct or remote (e.g., teleoperated). 
     In some embodiments, user interface  120  will be provided with the same degrees of freedom as the associated surgical instrument  140  to provide the clinician with telepresence, or the perception that control interface(s) in user interface  120  are integral with instruments  140  so that the clinician has a strong sense of directly controlling instruments  140  (although in other embodiments, user interface  120  may have more or less degrees of freedom than surgical instrument  140 ). In some embodiments, the user interface  120  can include manual input devices which move with six degrees of freedom and which may also include an actuatable handle for actuating instruments (for example, for closing grasping jaws, applying an electrical potential to an electrode, delivering a medicinal treatment, or the like). In other embodiments, user interface  120  can include switches, dials, or other adjustment interfaces to control the operational parameters of instrument  140 . 
     Optional display  130  may display an image of the surgical site and surgical instruments captured by one or more imaging elements of system  100 . In some embodiments, instrument  140  can include a camera system (e.g., an endoscope) to provide the imaging information. Alternatively or additionally, display  130  may present images of the surgical site recorded and/or modeled preoperatively and/or intraoperatively by an external imaging system that can use imaging technology such, as computerized tomography (CT), magnetic resonance imaging (MRI), positron emission tomography (PET), fluoroscopy, thermography, ultrasound, optical coherence tomography (OCT), thermal imaging, impedance imaging, laser imaging, or nanotube A-ray imaging, among others. The presented images may include two-dimensional, three-dimensional, or four-dimensional images. Note that as used herein, “external imaging” or “external image” refers to an image of the target anatomy taken from outside the patient as opposed to “in-situ” images taken from within the patient, regardless of the specific imaging modality (e.g., ultrasound can be used for both external imaging and/or in-situ imaging). 
     In some embodiments, the display system  130  may alternatively or additionally display a virtual navigational image in which the actual location of the surgical instrument is registered (i.e., dynamically reference) with preoperative or intra operative images to present the clinician S with a virtual image of the internal surgical site at the location of the tip of the surgical instrument. An image of the tip of the surgical instrument or other graphical or alphanumeric indicators may be superimposed on the virtual image to assist the clinician controlling the surgical instrument. Alternatively, the surgical instrument may not be visible in the virtual image. 
     In other embodiments, the display system  130  may alternatively or additionally display a virtual navigational image in which the actual location of the surgical instrument is registered with preoperative or concurrent intraoperative images to present the clinician with a virtual image of the surgical instrument within the surgical site from an external viewpoint. An image of a portion of the surgical instrument or other graphical or alphanumeric indicators may be superimposed on the virtual image to assist the clinician controlling the surgical instrument. 
     Instrument  140  include an instrument connector  150  that mates with a console connector  160  on control console  110  to provide coupling between instrument  140  and control console  110 . As shown in  FIG. 1 , instrument connector  150  and console connector  160  can be disengaged to disconnect instrument  140  from console  110 . Instrument  140  includes a primary transmission channel  154  for a first mode of operative communication, and at least one secondary transmission channel  155  for a second mode of operative communication. Each mode of operative communication represents an operative input and/or output to instrument  140 , such as data transmission, energy delivery, material delivery/removal, or any other type of interaction required by instrument  140  during use. 
     For illustrative purposes, instrument  140  is described below as an endoscope, which requires a first pathway for high intensity illumination (channel  154 ) and a second pathway for imaging controls/captured image data (channel  155 ). However, in various other embodiments, an endoscope might also include alternative or additional pathways for irrigation and/or suction. And in various other embodiments, instrument  140  can be any instrument that includes two or more discrete transmission channels, such as an ablation catheter with an RF energy input pathway and an irrigation pathway, or an electrosurgical dissection/coagulation tool having a fluid flow pathway and an electrical energization pathway, among others. 
     Instrument connector  150  includes primary engagement feature  152  coupled to primary transmission channel  154 , and a secondary engagement feature  153  coupled to secondary transmission channel  155 . Console connector  160  includes a corresponding primary engagement feature  162  coupled to primary transmission channel  164  and a secondary engagement feature  163  coupled to secondary transmission channel  165 . When instrument connector  150  and console connector  160  are mated, features  152  and  162  are engaged, and features  153  and  163  are engaged, thereby allowing transmission between instrument  140  and console  110  along primary transmission channels  154 / 164  and secondary transmission channels  155 / 165 . 
       FIG. 2  shows an exemplary embodiment of instrument connector  150  that includes a connector housing  151  that contains primary engagement feature  152  and secondary engagement feature  153  for primary transmission channel  154  and secondary transmission channel  155 , respectively, in instrument  140  (not shown for clarity). Primary engagement feature  152  can include an optional engagement lock  156  for establishing a fully connected condition, as described in greater detail below. While depicted and described herein as a basic groove for exemplary purposes, in various other embodiments, engagement lock can take any form (e.g., ridge(s), multiple grooves, flat face(s), clip-ring, etc.) and can be passive as shown or active (e.g., spring-loaded latch, clamp, etc.) and can be automatically or manually engaged and/or released. 
     As noted above, in various embodiments, instrument connector  150  can include multiple secondary engagement features  153  for multiple secondary transmission channels  155 . Not further that while primary engagement feature  152  is depicted as a single cylindrical pin for exemplary purposes, in various other embodiments, primary engagement feature  152  can have any shape (e.g., non-circular pin, tapered pin, prismatic rod, sheath with or without additional interior elements, etc.) any quantity (e.g., multiple pins or other features). Likewise, while secondary engagement feature  153  is depicted as a rectangularly protrusion within a slot for exemplary purposes, in various other embodiments, secondary engagement feature  153  can take any form (e.g., empty slot, socket, pins, etc.) and quantity. In addition, although housing  151  is depicted as a axially asymmetrical shape (pentagon) for exemplary purposes, in various other embodiments, housing  151  can take any shape (e.g., circular, square, rectangular, triangular, oval, etc.). 
       FIG. 3  shows an exemplary embodiment of console connector  160  that includes a connector housing  161  that contains primary engagement feature  162  and secondary engagement feature  163  for primary transmission channel  164  and secondary transmission channel  165 , respectively, in console  110  (not shown for clarity). Primary engagement feature  162  can include an optional engagement lock  166  for establish a fully connected condition, as describe in greater detail below. While depicted and described herein as a compliant ridge (e.g., coil spring, o-ring, spring-loaded ball( ) for exemplary purposes, in various other embodiments, engagement lock  166  can take any form (e.g., clamp, latch, hook, etc.) and can be active as shown or passive (e.g., groove(s), slot(s), etc.) and can be automatically or manually engaged and/or released. 
     As noted above, in various embodiments, console connector  160  can include multiple secondary engagement features  163  for multiple secondary transmission channels  155 . Note further that while primary engagement feature  162  is depicted as a single cyclical socket for exemplary purposed, in various other embodiments, primary engagement feature  162  can have any shape (e.g., non-circular socket, tapered socket, prismatic socket, socket with or without additional interior elements, mating pins, etc.) any quantity (e.g., multiple sockets/pins or other features). Likewise, while secondary engagement feature  163  is depicted as a rectangular protruding slot for exemplary purposes, in various other embodiments, secondary engagement feature  163  can take any form (e.g., empty slot, socket, pins, etc.) and quantity. In addition, although housing  161  is depicted as a axially asymmetrical shape (pentagon) for exemplary purposes, in various other embodiments, housing  151  can take any shape (e.g., circular, square, rectangular, triangular, oval, etc.) 
       FIGS. 4A-4E  show an exemplary engagement operation between instrument connector  150  and console connector  160 . In  FIG. 4A , connectors  150  and  160  are positioned relative to one another in preparation for making a connection. Then in  FIG. 4B , primary engagement feature  152  of instrument connector  150  begins to interact with console connector housing  161  as connectors  150  and  160  are moved towards each other. In this manner, primary engagement feature  152  establishes an initial relative positioning between connectors  150  and  160 . 
     In some embodiments, primary engagement feature  152  can be a robust structural element that can be used for gross initial positioning movements with minimal risk of damage to itself, can also serve to minimize the risk of damage to secondary connector  153 , and/or can provide precise relative positioning between secondary connectors  153  and  163  prior to engagement, as described in greater detail below. For example, in some embodiments, primary engagement feature  152  can be a metal (e.g., stainless steel) rod or tube, sized to mate with a corresponding metal socket in primary engagement feature  162  in connector  160 . 
     In  FIG. 4B , instrument connector housing  151  begins to interact with console connector housing  161 . In some embodiments, where connector housing  151  and console housing  161  are axially asymmetrical (e.g., pentagonal shape as shown in  FIGS. 2 and 3 ), this interaction can enforce a proper rotational orientation of instrument connector  150  with respect to console connector  160 . In other embodiments, this rotational orientation can be established by an initial engagement of primary engagement feature  152  (e.g., if an axially asymmetrical pin, multiple pins, etc.) with primary engagement feature  162 , or by separate orientation features (e.g., rails or slots on connector housings  151  and/or  161 ). 
     Primary engagement feature  152  also begins to engage with primary engagement feature  162 . Features  152  and  162  can in various embodiments include chamfers, tapers, or any other features to assist in alignment as the features begin to interact with each other. Then, as shown in  FIG. 4D , as primary engagement features  152  and  162  become increasingly mated, secondary engagement features  153  and  163  begin to engage, having been previously aligned by the mating of features  152  and  162  and optionally additionally by the mating of housings  151  and  161 . 
     Finally, full engagement of connectors  150  and  160  is shown in  FIG. 4E . As noted above, in some embodiments, primary engagement features  152  and  162  can optionally include locking features  156  and  166 , respectively, that establish the final relative positioning of connectors  150  and  160 . For example, locking-feature  166  could be a canted coil spring, o-ring, expanding clip, or any other compliant or movable element/feature mounted in engagement feature  162  that nests into a groove corresponding to locking feature  156  when proper connector mating is achieved, and prevents further insertion to prevent damage to either connector. However, in various other embodiments, full engagement of the connectors could be established by opposing faces of housings  151  and  161 , by secondary engagement features  153 / 163 , or by any other means. 
     Thus, by establishing an accurate alignment of connector  150  with connector  160 , primary engagement features  152  and  162  and/or connector housings  151  and  162  ensure that secondary engagement features  153  and  163  can be accurately engaged with minimal risk of damage. This can be particularly beneficial where secondary engagement features  153  and/or  163  are delicate or difficult/costly to replace (e.g., electrical connectors for imaging or sensor data transmission). 
     For example, an endoscope requires both a high intensity illumination light input and an electrical signal input/output for imaging controls and data. A bundle or optical fibers are often used to transport the illumination light from the light source to the distal tip of the endoscope. In some embodiments, primary engagement feature  162  in console connector  160  can be coupled to the transmission channel ( 164 ) from this high intensity light source, and primary engagement feature  152  in instrument connector  150  can be coupled to the transmission channel ( 155 ) that conveys the light to the endoscope tip. In such a construction, the rigidity and robustness of primary engagement feature  152  can provide the additional benefit of precisely controlling the alignment of the source transmission channel ( 164 ) with the instrument transmission channel ( 154 ), which can have a significant effect on lighting efficiency. Other types of transmission channels requiring precision alignment for proper communication across the connection (e.g., optical fiber connections for shape or force sensing, precision coaxial connectors, etc.) can similarly benefit from integration into the engagement feature itself. 
     In some embodiments, primary engagement features  152  and  162  and/or secondary engagement features  153  and  163  can include safety mechanisms to prevent inadvertent discharge from any of the transmission channels. For example,  FIG. 4D  shows an optional shutter mechanism  167  (e.g., a pivoting panel, expanding iris, or any other movable cover) mounted on primary engagement feature  162  in console connector  160 . Shutter mechanism  167  is normally closed, thereby blocking any undesirable discharge from transmission channel  164  (for example, high intensity laser illumination light or electrical power). As engagement feature  152  mates with engagement feature  162 , shutter mechanism  167  is moved out of the way once a safe degree of engagement is achieved to allow the operational coupling of transmission channels  154  and  164 . 
     In some embodiments, primary engagement feature  152  and/or housing  151  can further ensure proper connector engagement when instrument connector  150  and console connector  160  are not properly aligned. For example,  FIG. 5A  shows connector  150  angled upwards with respect to connector  160 . However, the initial interaction of primary engagement feature  152  with housing  161  tends to straighten connector  150  with respect to connector  160 , as shown in  FIG. 5B . Continued advancement further aligns connectors  150  and  160 , so that eventually primary engagement feature  152  can begin to properly mate with primary engagement feature  162 , as shown in  FIG. 5C . The connection can then be completed as described above with respect to  FIGS. 4C-4E . 
     Similarly,  FIG. 6A  shows connector  150  angled downwards with respect to connector  160 . Housing  151  is shaped and sized such that as connector  150  is aligned with connector  160  as it is further advanced towards connector  160 , as shown in  FIG. 6B . this also aligns primary engagement feature  152  with primary engagement feature  162 , thereby allowing completion of the connections as described above with respect to  FIGS. 4C-4E . 
     In various other embodiments, the robustness and reliability of the connection can be further enhanced by sizing/shaping primary engagement features  152 / 162 , secondary engagement features  153 / 163 , and/or housings  151 / 161  to ensure that potentially damaging contract cannot be made between the various engagement features. For example, as shown in  FIG. 7 , primary engagement feature  152  of instrument connector  150  can be sized such that it cannot contact secondary engagement feature  163  of console connector  160 . In the exemplary depiction of  FIG. 7 , primary engagement feature  152  extends a distance from the outer face of connector housing  151  that is less than the depth at which secondary engagement feature  163  is recessed from the outer face of connector housing  161 . However, various other housing/feature configurations could be implemented to provide a similar degree of enforced separation, such as sizing console housing  161  around secondary engagement feature  163  such that primary engagement feature  152  cannot fit within the access space (e.g., an opening smaller than or non-congruent with the cross-sectional shape of engagement feature  152 ). 
     While certain exemplary embodiments of the invention have been described and shown in the accompanying drawings, it is to be understood that such embodiments are merely illustrative of and not restrictive on the broad invention, and that the embodiments of the invention not be limited to the specific constructions and arrangements shown and described, since various other modifications may occur to those ordinarily skilled in the art.