Patent Description:
<CIT> discloses an instrument interface of a robotic manipulator and a surgical system including the instrument interface. The instrument interface includes a spring-loaded input for providing axial load and torque to a sterile adaptor capable of operably coupling an instrument. A robotic surgical manipulator system includes a manipulator assembly, including a base link operably coupled to a distal end of a manipulator arm, and a carriage link movably coupled to the base link along a lengthwise axis, the carriage link including an integrated instrument interface. The system includes an instrument operably coupled to the carriage link via the instrument interface, and a processor operably coupled to the manipulator assembly for sensing presence of the instrument.

<CIT> discloses a surgical instrument arrangement having a modular motor drive unit which has a drive arrangement with an output element and an instrument shaft which is detachably connected to the drive unit. The drive arrangement is provided with an input drive element. The output arrangement and the drive arrangement are coupled to each other by a mechanical interface which has a single-sided linkage, a pin and a cut-out. The pin is expanded in the cut-out radially, particular elastically or by a separate body.

<CIT> discloses a master manipulator for operating driving of a slave manipulator. The master manipulator includes a grip portion that is positioned in a clean area, gripped by an operator, and provided with a predetermined operating member; and an arm portion that is positioned in an unclean area, and with which the grip portion is connected. The grip portion has a movable member that moves in conjunction with displacement of the operating member; and the arm portion has a position detection portion that detects the position of the movable member.

Embodiments of the invention relate to the field of latches; and more specifically, to latch assemblies for coupling actuators to surgical instruments. Background.

Minimally invasive medical techniques have been used to reduce the amount of extraneous tissue which may be damaged during diagnostic or surgical procedures, thereby reducing patient recovery time, discomfort, and deleterious side effects. Traditional forms of minimally invasive surgery include endoscopy. One of the more common forms of endoscopy is laparoscopy, which is minimally invasive inspection or surgery within the abdominal cavity. In traditional laparoscopic surgery, a patient's abdominal cavity is insufflated with gas, and cannula sleeves are passed through small (approximately <NUM>) incisions in the musculature of the patient's abdomen to provide entry ports through which laparoscopic surgical instruments can be passed in a sealed fashion.

The laparoscopic surgical instruments generally include a laparoscope for viewing the surgical field and surgical instruments having end effectors. Typical surgical tools include clamps, graspers, scissors, staplers, and needle holders, for example. The surgical instruments are similar to those used in conventional (open) surgery, except that the end effector of each surgical instrument is separated from its handle by an approximately <NUM>. long extension tube, for example, so as to permit the operator to introduce the end effector to the surgical site and to control movement of the end effector relative to the surgical site from outside a patient's body.

In order to provide improved control of the working tools, it may be desirable to control the instrument with teleoperated actuators. The surgeon may operate controls on a console to indirectly manipulate the instrument that is connected to the teleoperated actuators. The instrument is detachably coupled to the teleoperated actuators so that the instrument can be separately sterilized and selected for use as needed instrument for the surgical procedure to be performed. The instrument may be changed during the course of a surgery.

Performing surgery with teleoperated surgical instruments creates new challenges. One challenge is the need to maintain the region adjacent the patient in a sterile condition. However, the motors, sensors, encoders and electrical connections that are necessary to control the surgical instruments typically cannot be sterilized using conventional methods, e.g., steam, heat and pressure or chemicals, because they would be damaged or destroyed in the sterilization process.

Another challenge with teleoperated surgery systems is that a surgeon will typically employ a large number of different surgical instruments during a procedure. Since the number of instrument holders are limited due to space constraints and cost, many of these surgical instruments will be attached and detached from the same instrument holder a number of times during an operation. In laparoscopic procedures, for example, the number of entry ports into the patient's abdomen is generally limited during the operation because of space constraints as well as a desire to avoid unnecessary incisions in the patient. Thus, a number of different surgical instruments will typically be introduced through the same trocar sleeve during the operation. Likewise, in open surgery, there is typically not enough room around the surgical site to position more than one or two surgical manipulators, and so the surgeon's assistant will be compelled to frequently remove instruments from the teleoperated actuated manipulator and exchange them with other surgical tools.

It would be desirable to provide an easier and more effective way to engage and disengage a surgical instrument and a teleoperated actuator drive while preventing contamination of the teleoperated actuator and allowing quick and reliable attachment of a succession of surgical instruments that maintains a sterile area around the surgical instrument.

The invention is set out in the appended independent claim. Optional features are set out in the appended dependent claims.

The invention may best be understood by referring to the following description and accompanying drawings that are used to illustrate embodiments of the invention by way of example and not limitation. In the drawings, in which like reference numerals indicate similar elements:.

In the following description, numerous specific details are set forth. In other instances, well-known circuits, structures, and techniques have not been shown in detail in order not to obscure the understanding of this description.

In the following description, reference is made to the accompanying drawings, which illustrate several embodiments of the present invention. It is understood that other embodiments may be utilized, and mechanical compositional, structural, electrical, and operational changes may be made without departing from the scope of the present disclosure. The following detailed description is not to be taken in a limiting sense, and the scope of the embodiments of the present invention is defined only by the appended claims.

Spatially relative terms, such as "beneath", "below", "lower", "above", "upper", and the like may be used herein for ease of description to describe one element's or feature's relationship to another element(s) or feature(s) as illustrated in the figures. The device may be otherwise oriented (e.g., rotated <NUM> degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly.

As used herein, the singular forms "a," "an," and "the" are intended to include the plural forms as well, unless the context indicates otherwise. It will be further understood that the terms "comprises" and/or "comprising" specify the presence of stated features, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, steps, operations, elements, components, and/or groups thereof.

The term "object" generally refers to a component or group of components. For example, an object may refer to either a pocket or a boss of a disk within the specification or claims. Throughout the specification and claims, the terms "object," "component," "portion," "part" and "piece" are used interchangeably.

The terms "instrument" and "surgical instrument "are used herein to describe a medical device configured to be inserted into a patient's body and used to carry out surgical or diagnostic procedures. The instrument includes an end effector. The end effector may be a surgical tool associated with one or more surgical tasks, such as a forceps, a needle driver, a shears, a bipolar cauterizer, a tissue stabilizer or retractor, a clip applier, an anastomosis device, an imaging device (e.g., an endoscope or ultrasound probe), and the like. Some instruments used with embodiments of the invention further provide an articulated support (sometimes referred to as a "wrist") for the surgical tool so that the position and orientation of the surgical tool can be manipulated with one or more mechanical degrees of freedom in relation to the instrument's shaft. Further, many surgical end effectors include a functional mechanical degree of freedom, such as jaws that open or close, or a knife that translates along a path. Surgical instruments may also contain stored (e.g., on a semiconductor memory inside the instrument) information that may be permanent or may be updatable by the surgical system. Accordingly, the system may provide for either one-way or two-way information communication between the instrument and one or more system components.

The terms "or" and "and/or" as used herein are to be interpreted as inclusive or meaning any one or any combination. Therefore, "A, B or C" or "A, B and/or C" mean "any of the following: A; B; C; A and B; A and C; B and C; A, B and C. " An exception to this definition will occur only when a combination of elements, functions, steps or acts are in some way inherently mutually exclusive.

<FIG> is a view of an illustrative patient-side portion <NUM> of a teleoperated surgical system, in accordance with embodiments of the present invention. The patient-side portion <NUM> includes support assemblies <NUM> and one or more instrument carriages <NUM> that include actuators and control connections for surgical instruments at the end of each support assembly. The support assemblies optionally include one or more unpowered, lockable setup joints that are used to position the instrument manipulator(s) <NUM> with reference to the patient for surgery. As depicted, the patient-side portion <NUM> rests on the floor. In other embodiments the patient-side portion may be mounted to a wall, to the ceiling, to the operating table <NUM>, which also supports the patient's body <NUM>, or to other operating room equipment. Further, while the patient-side portion <NUM> is shown as including four instrument manipulators <NUM>, more or fewer instrument manipulators may be used. Still further, the patient-side portion <NUM> may consist of a single assembly as shown, or it may include two or more separate assemblies, each optionally mounted in various possible ways.

Each setup joint supports one or more instrument manipulators <NUM>. Each instrument manipulator <NUM> includes an instrument carriage <NUM> that supports a surgical instrument <NUM> for operating at a surgical site within the patient's body <NUM>. Each instrument manipulator <NUM> may be provided in a variety of forms that allow the associated surgical instrument to move with one or more mechanical degrees of freedom (e.g., all six Cartesian degrees of freedom, five or fewer Cartesian degrees of freedom, etc.). Typically, mechanical or control constraints restrict each instrument manipulator <NUM> to move its associated surgical instrument around a center of motion on the surgical instrument that stays stationary with reference to the patient, and this center of motion is typically located to be at the position where the surgical instrument enters the body.

The term "surgical instrument" is used herein to describe a medical device configured to be inserted into a patient's body and used to carry out surgical or diagnostic procedures. The surgical instrument typically includes an end effector associated with one or more surgical tasks, such as a forceps, a needle driver, a shears, a bipolar cauterizer, a tissue stabilizer or retractor, a clip applier, an anastomosis device, an imaging device (e.g., an endoscope or ultrasound probe), and the like. Some surgical instruments used with embodiments of the invention further provide an articulated support (sometimes referred to as a "wrist") for the end effector so that the position and orientation of the end effector can be manipulated with one or more mechanical degrees of freedom in relation to the instrument's shaft. Further, many surgical end effectors include a functional mechanical degree of freedom, such as jaws that open or close, or a knife that translates along a path. Surgical instruments may also contain stored (e.g., on a semiconductor memory inside the instrument) information that may be permanent or may be updatable by the surgical system. Accordingly, the system may provide for either one-way or two-way information communication between the instrument and one or more system components.

A functional teleoperated surgical system will generally include a vision system portion (not shown) that enables the operator to view the surgical site from outside the patient's body <NUM>. The vision system typically includes a surgical instrument that has a video-image-capture function (a camera instrument <NUM>) and one or more video displays for displaying the captured images. In some surgical system configurations, the camera instrument <NUM> includes optics that transfer the images from the distal end of the camera instrument <NUM> to one or more imaging sensors (e.g., CCD or CMOS sensors) outside of the patient's body <NUM>. Alternatively, the imaging sensor(s) may be positioned at the distal end of the camera instrument <NUM>, and the signals produced by the sensor(s) may be transmitted along a lead or wirelessly for processing and display on the video display. An illustrative video display is the stereoscopic display on the surgeon's console in surgical systems commercialized by Intuitive Surgical, Inc. , Sunnyvale, California.

A functional teleoperated surgical system will further include a control system portion (not shown) for controlling the movement of the surgical instruments <NUM> while the instruments are inside the patient. The control system portion may be at a single location in the surgical system, or it may be distributed at two or more locations in the system (e.g., control system portion components may be in the system's patient-side portion <NUM>, in a dedicated system control console, or in a separate equipment rack). The teleoperated master/slave control may be done in a variety of ways, depending on the degree of control desired, the size of the surgical assembly being controlled, and other factors. In some embodiments, the control system portion includes one or more manually-operated input devices, such as a joystick, exoskeletal glove, a powered and gravity-compensated manipulator, or the like. These input devices control teleoperated motors which, in turn, control the movement of the surgical instrument.

The forces generated by the teleoperated motors are transferred via drivetrain mechanisms, which transmit the forces from the teleoperated motors to the surgical instrument <NUM>. In some telesurgical embodiments, the input devices that control the manipulator(s) may be provided at a location remote from the patient, either inside or outside the room in which the patient is placed. The input signals from the input devices are then transmitted to the control system portion. Persons familiar with telemanipulative, teleoperative, and telepresence surgery will know of such systems and their components, such as the da Vinci® Surgical System commercialized by Intuitive Surgical, Inc. and the Zeus® Surgical System originally manufactured by Computer Motion, Inc. , and various illustrative components of such systems.

As shown, both the surgical instrument <NUM> and an optional entry guide <NUM> (e.g., a cannula in the patient's abdomen) are removably coupled to the distal end of an instrument manipulator <NUM>, with the surgical instrument <NUM> inserted through the entry guide <NUM>. Teleoperated actuators in the instrument manipulator <NUM> move the surgical instrument <NUM> as a whole. The instrument manipulator <NUM> further includes an instrument carriage <NUM>. The surgical instrument <NUM> is detachably connected to the instrument carriage <NUM>. The teleoperated actuators housed in the instrument carriage <NUM> provide a number of controller motions which the surgical instrument <NUM> translates into a variety of movements of the end effector on the surgical instrument. Thus the teleoperated actuators in the instrument carriage <NUM> move only one or more components of the surgical instrument <NUM> rather than the instrument as a whole. Inputs to control either the instrument as a whole or the instrument's components are such that the input provided by a surgeon to the control system portion (a "master" command) is translated into a corresponding action by the surgical instrument (a "slave" response).

<FIG> is a side view of an illustrative embodiment of the surgical instrument <NUM>, comprising a distal portion <NUM> and a proximal control mechanism <NUM> coupled by an elongate tube <NUM>. The distal portion <NUM> of the surgical instrument <NUM> may provide any of a variety of surgical tools, such as the forceps <NUM> shown, a needle driver, a cautery device, a cutting tool, an imaging device (e.g., an endoscope or ultrasound probe), or a combined device that includes a combination of two or more various tools and imaging devices. In the embodiment shown, the forceps <NUM> are coupled to the elongate tube <NUM> by a "wrist joint" <NUM> that allows the orientation of the forceps to be manipulated with reference to the elongate tube <NUM>.

Surgical instruments that are used with the invention may control their end effectors (surgical tools) with a plurality of rods and/or flexible cables. Rods, which may be in the form of tubes, may be combined with cables to provide a "push/pull" control of the end effector with the cables providing flexible sections as required. A typical elongate tube <NUM> for a surgical instrument <NUM> is small, perhaps five to eight millimeters in diameter, roughly the diameter of a large soda straw. The diminutive scale of the mechanisms in the surgical instrument <NUM> creates unique mechanical conditions and issues with the construction of these mechanisms that are unlike those found in similar mechanisms constructed at a larger scale, because forces and strengths of materials do not scale at the same rate as the size of the mechanisms. The cables must fit within the elongate tube <NUM> and be able to bend as they pass through the wrist joint <NUM>.

In order to provide a sterile operation area while using a functional teleoperated surgical system, it is preferred that a barrier be placed between the actuating portion of the teleoperated surgical system and the surgical instruments in the sterile surgical field. Therefore, a sterile component, such as an instrument sterile adapter (ISA), is placed between the surgical instrument <NUM> and the teleoperated controls in the instrument carriage <NUM>. The placement of an instrument sterile adapter between the surgical instrument <NUM> and the instrument carriage <NUM> includes the benefit of ensuring a sterile coupling point for the surgical instrument <NUM> and the instrument carriage <NUM>. This permits removal of surgical instruments from the instrument carriage <NUM> and exchange with other surgical instruments during the course of a surgery.

<FIG> is a perspective view of a setup joint that supports the instrument carriage <NUM> which in turn supports the surgical instrument <NUM> on a strut <NUM>. In preparation for surgery, the setup joint is covered with a sterile drape <NUM>. The sterile drape protects the setup joint from contamination and provides a sterile surface around the setup joint. The majority of the sterile drape <NUM> is a plastic sheet, which may be in the form of a tube or bag, that covers the arms of the setup joint. For example, a single layer thermoplastic polyurethane (TPU) may be used. A lubricant may be included to reduce the tackiness of the plastic. The sheet may be about <NUM> (<NUM>") thick. Other suitable materials may be used for the sheet. The sterile drape <NUM> includes a pouch portion <NUM> that is formed to fit around the instrument carriage <NUM>.

<FIG> is a perspective view of the pouch portion <NUM> of the sterile drape <NUM> shown in <FIG>. The pouch portion <NUM> includes a sterile cover <NUM> and an instrument sterile adapter <NUM>. The instrument carriage may contain motors, electrical power, and control signals used by a control system to drive the surgical instrument. The instrument sterile adapter <NUM> transfers motion and electrical signals between the instrument carriage <NUM> and a proximal control mechanism <NUM> of a surgical instrument <NUM> connected to the sterile side of the instrument sterile adapter <NUM>. The instrument sterile adapter <NUM> includes a latch plate provided to secure the connections between instrument sterile adapter <NUM> and instrument carriage <NUM> and between instrument sterile adapter <NUM> and surgical instrument <NUM>.

<FIG> is a side elevation of the instrument sterile adapter <NUM> from the sterile drape. <FIG> is an exploded view of the instrument sterile adapter. The instrument sterile adapter includes a latch plate <NUM> and an instrument plate <NUM> that are joined together to capture a portion of the pouch <NUM> between the two plates. The latch plate <NUM> provides a surface <NUM> to be joined to the instrument carriage <NUM>. The instrument plate <NUM> provides a surface <NUM> to receive a surgical instrument <NUM>. Other components used to transfer control motion and signals between a surgical instrument <NUM> and the instrument carriage <NUM>, such a coupler disks <NUM> and presence pins <NUM>, may also be captured between the latch plate <NUM> and the instrument plate <NUM>. The latch plate <NUM> further provides latches that hold the instrument sterile adapter <NUM> on the instrument carriage <NUM> and hold the surgical instrument <NUM> on the instrument sterile adapter.

Referring to <FIG>, <FIG>, a top perspective view, a bottom perspective view, an elevation view, and cross-section views of a latch plate <NUM> according to one embodiment of the invention are illustrated, respectively. The latch plate <NUM> includes a pair of instrument latch arms <NUM> on a first side of the latch plate, and includes a pair of carriage latch arms <NUM> on a second side. The instrument latch arms <NUM> are longer than the carriage latch arms <NUM>. A penetrating opening or aperture is provided toward the end portion of each of the latch arms <NUM>, <NUM>, acting as latch receivers. Therefore, each of the instrument latch arms <NUM> includes an instrument latch receiver <NUM>, and each of the carriage latch arms <NUM> includes a carriage latch receiver <NUM>. The instrument latch arms <NUM> are used to secure a surgical instrument <NUM> to the instrument sterile adapter <NUM>, and the carriage latch arms <NUM> are used to secure the instrument sterile adapter <NUM> to an instrument carriage.

<FIG> is a cross-section view of latch plate <NUM> through the plane indicated by section line <NUM>--<NUM> in <FIG>. As can be seen in <FIG>, the instrument latch arms <NUM>, the carriage latch arms <NUM>, and connecting members <NUM> may be formed in one piece with the latch plate <NUM>, and may be made of a flexible material that returns to its original shape when no external force is applied, such as a plastic material.

<FIG> show cross-section views of a single latch arm structure in isolation through the plane indicated by section line <NUM>-<NUM> in <FIG>. An instrument latch arm <NUM>, a corresponding carriage latch arm <NUM>, and a corresponding connecting member <NUM> form a "T" shape, with the latch arms <NUM>, <NUM> being the two arms of the letter T, and the connecting member <NUM> being the stem of the letter T. The instrument latch arm extends through the instrument plate <NUM> and away from the surface <NUM> of the instrument plate that receives the surgical instrument. The carriage latch arm <NUM> extends away from the surface <NUM> of the latch plate <NUM> that receives the instrument carriage <NUM>. The instrument latch arm <NUM> is joined to the carriage latch arm <NUM> at a junction. The connecting member <NUM> is joined to both arms at the junction. The connecting member <NUM> is perpendicular to the carriage latch arm and the instrument latch arm when in its undeformed configuration. As suggested by <FIG>, portions of the latch arm structure may be elastically deformed for latching and unlatching. The connecting member <NUM> provides a flexible connection of the carriage latch arm <NUM> and the instrument latch arm <NUM> to a remainder of the latch plate <NUM>. Skilled artisan may appreciate that features may be provided to prevent any of elements discussed above from being deformed past its elastic range.

<FIG> shows the latch arms <NUM>, <NUM> and the connecting member <NUM> in their original state. <FIG> shows the latch arms <NUM>, <NUM> and the connecting member <NUM> in a bent state where the instrument latch arm <NUM> has moved away from the center line of the latch plate <NUM>, the carriage latch arm <NUM> has moved toward the center line of the latch plate, and the connecting member <NUM> has moved upwardly toward the carriage latch arm.

As can be seen in <FIG>, the latch arms <NUM>, <NUM> may be slightly and pivotally bent inward or outward approximately around the corresponding connecting member <NUM> when forces are applied to the latch arms, and of course, the corresponding connecting member <NUM> may be slightly deformed accordingly. In other words, when an inward or outward force is applied to a latch arm <NUM>, <NUM>, a Class <NUM> lever is formed with the corresponding connecting member <NUM> being approximately the fulcrum. (A Class <NUM> lever is a lever in which the fulcrum is situated between the effort and the resistance. ) Absent interference from other objects, bending an instrument latch arm <NUM> inward causes the corresponding carriage latch arm <NUM> to move outward, and vice versa. Bending a carriage latch arm <NUM> has the same effects on the corresponding instrument latch arm <NUM>.

<FIG>, <FIG>, <FIG>, and <FIG> are cross-section views of the instrument sterile adapter <NUM> including a latch plate <NUM> through the plane indicated by section line <NUM>--<NUM> in <FIG>. <FIG>, <FIG>, <FIG>, and <FIG> show the assembly sequence of the instrument sterile adapter <NUM> to a control surface <NUM> of an instrument carriage <NUM> and a proximal control mechanism <NUM> of a surgical instrument <NUM> to the instrument sterile adapter.

Referring to <FIG>, the control surface <NUM> of the instrument carriage includes a first fixed latch structure that provides two first angled lead-in latch surfaces <NUM> leading to two first locking surfaces <NUM>. The first fixed latch structure may be made of a rigid material that does not deform easily. The two first angled lead-in latch surfaces <NUM> help guide the carriage latch arms <NUM> into the first fixed carriage latch structure when one attempts to attach the instrument sterile adapter <NUM> to the control surface <NUM>. The instrument sterile adapter <NUM> typically includes a translucent pouch that surrounds the instrument carriage <NUM> when the instrument sterile adapter <NUM> is attached to the control surface <NUM>. The pouch may largely obstruct the view of the carriage latch structure as the instrument sterile adapter <NUM> is being attached to the control surface <NUM>. The two first angled lead-in latch surfaces <NUM> may provide a "saddle-like" receiving surface for the carriage latch arms <NUM> facilitating the attachment of the instrument sterile adapter <NUM> to the control surface <NUM> by feel. When the instrument sterile adapter <NUM> is being attached to the control surface <NUM>, the angled lead-in latch surfaces <NUM> will cause the latch arm structures to elastically deform to allow the carriage latch arms <NUM> to pass over the angled lead-in latch surfaces.

Referring to <FIG>, when the instrument sterile adapter <NUM> is attached to the control surface <NUM>, the first locking surfaces <NUM> of the control surface <NUM> engage the carriage latch receivers <NUM> of the carriage latch arms <NUM> of the latch plate <NUM>. The elastic deformation of the latch arm structures is largely released when the carriage latch receivers <NUM> engage the first locking surfaces <NUM>. This secures the instrument sterile adapter <NUM> to the control surface <NUM>. The carriage latch structure of the control surface <NUM> supports the carriage latch arms <NUM> and prevents them from rotating inwardly toward each other. This in turn prevents the connecting members <NUM> from bending from their undeformed configuration.

Referring to <FIG>, the proximal control mechanism <NUM> includes a second fixed latch structure that provides two second angled lead-in latch surfaces <NUM> leading to two second locking surfaces <NUM>. The lead-in ramps <NUM> may be formed as part of the instrument latch structure. The second fixed latch structure may be made of a rigid material that does not deform easily. The second fixed instrument latch structure of the proximal control mechanism <NUM> further includes two lead-in ramps <NUM> that help guide the instrument latch arms <NUM> of the instrument sterile adapter <NUM> into the instrument latch structure when one attempts to attach the proximal control mechanism <NUM> to the instrument sterile adapter <NUM>. The help afforded by the lead-in ramps <NUM> is desirable because direct view of relevant components is partially or fully obstructed by the proximal control mechanism <NUM>, which is enclosed by a housing not shown in <FIG> but which can be seen in <FIG>.

Referring to <FIG>, when the proximal control mechanism <NUM> of the surgical instrument <NUM> is attached to the instrument sterile adapter <NUM>, the second locking surfaces <NUM> of the proximal control mechanism <NUM> engage the instrument latch receivers <NUM> of the instrument latch arms <NUM> of the latch plate <NUM>. This secures the proximal control mechanism <NUM> of the surgical instrument <NUM> to the instrument sterile adapter <NUM>. It will be appreciated that the instrument latch arms <NUM> must be sufficiently flexible to bend outwardly to pass over the second angled lead-in latch surfaces <NUM> because the connecting members <NUM> are prevented from bending toward the instrument carriage <NUM> by the carriage latch arms <NUM> when the instrument sterile adapter <NUM> is attached to the control surface <NUM>.

It should be appreciated that when both the proximal control mechanism <NUM> of the surgical instrument <NUM> and the control surface <NUM> of the instrument carriage are attached to the instrument sterile adapter <NUM>, the presence of the proximal control mechanism <NUM> constitutes a locking mechanism for the attachment of the instrument sterile adapter <NUM> to the instrument carriage <NUM>. Inward movement of the instrument latch arms <NUM> is prevented by the attached proximal control mechanism <NUM>. In turn, upward movement of the connecting members <NUM> away from the control surface is prevented by the constrained instrument latch arms <NUM>. As a result, outward movement of carriage latch arms <NUM> becomes difficult. The carriage latch arms <NUM> may be short and of a greater thickness to further increase the difficulty of disengaging the carriage latch arms when the proximal control mechanism <NUM> is attached to the instrument sterile adapter <NUM>. Because carriage latch arms <NUM> are prevented from being bent outward by the proximal control mechanism <NUM>, the instrument sterile adapter <NUM> is locked to the attached control surface <NUM>.

<FIG> show cross-section views of a single latch arm structure with the fixed latch structures of a control surface <NUM> of an instrument carriage <NUM> and a proximal control mechanism <NUM> through the plane indicated by section line <NUM>-<NUM> in <FIG>.

Referring to <FIG>, the instrument sterile adapter is being attached to the instrument carriage. To attach the instrument sterile adapter <NUM> to the control surface <NUM> of an instrument carriage <NUM>, one roughly aligns the instrument sterile adapter with the control surface, and pushes the instrument sterile adapter against the control surface. The first angled lead-in latch surface <NUM> can help guide the carriage latch arms <NUM> into the carriage latch structure and provide the necessary rough alignment. The latch arm structure of the instrument sterile adapter is shown at the point where elastic deformation of the latch arm structure is about to begin.

Referring to <FIG>, as the instrument sterile adapter is pressed toward the control surface, the latch arm structure of the instrument sterile adapter deforms to allow the carriage latch arm <NUM> to pass over the locking surface <NUM>. The connecting member <NUM> may be sized and shaped so that most of the elastic deformation occurs in the connecting member when the carriage latch arm <NUM> passes over the locking surface <NUM>. The connecting member <NUM> may be sufficiently flexible to cause the carriage latch arm <NUM> to rotate and allow the carriage latch arm to pass over the fixed locking surface <NUM> in the instrument carriage. As the instrument sterile adapter is being pushed against the control surface, the first angled latch surface <NUM> pushes the carriage latch arm <NUM> outward, allowing the instrument sterile adapter <NUM> to move toward the control surface.

Referring to <FIG>, the instrument sterile adapter is moved toward the control surface until the first locking surface <NUM> enters the carriage latch receiver <NUM>, at which time and the connecting member <NUM> may resume an original shape and cause the carriage latch arm <NUM> to engage the first fixed locking surface. The carriage latch arms <NUM> close in on the carriage latch structure, securing the instrument sterile adapter to the control surface of an instrument carriage <NUM>. In this condition the instrument sterile adapter is ready to receive a proximal control mechanism of a surgical instrument. In some embodiments, the pair of carriage latch arms <NUM> may be shaped and/or spaced such that when the pair of carriage latch arms <NUM> are closed on the carriage latch structure, the pair of carriage latch arms <NUM> are bent slightly outward compared to their natural shape so that they apply inward forces on the carriage latch structure to better secure the instrument sterile adapter to the instrument carriage.

Referring to <FIG>, the instrument latch arm <NUM> may be used as a release lever for the carriage latch arms <NUM>. The instrument latch arm <NUM> can receive a force <NUM> that bends the connecting member <NUM> sufficiently to cause the carriage latch arm <NUM> to rotate and allow the carriage latch arm pass over a fixed locking surface in the instrument carriage. By pressing the two instrument latch arms <NUM> toward the center of the latch plate <NUM> with a force <NUM> as indicated by the arrow, for example by pinching the two instrument latch arms, the carriage latch arms <NUM> are moved outwardly. This releases the carriage latch receiver <NUM> from the first locking surface <NUM> of the carriage latch structure and allows the instrument sterile adapter to be removed from the instrument carriage.

Referring to <FIG>, a proximal control mechanism of a surgical instrument is being attached to the instrument sterile adapter. The instrument sterile adapter is in the condition shown in Fig. C. To attach the proximal control mechanism of a surgical instrument to the instrument sterile adapter, one roughly aligns the proximal control mechanism with the instrument sterile adapter, and pushes the proximal control mechanism toward the instrument sterile adapter. The lead-in ramp <NUM> helps guide the instrument latch arm <NUM> into the fixed instrument latch structure and provides the necessary rough alignment. A transition section <NUM> may join the lead-in ramp <NUM> to the second locking surface <NUM>. The transition section <NUM> may be generally parallel to the undeformed instrument latch arm <NUM>. The transition section <NUM> may be located to closely fit against the instrument latch arm <NUM> when the proximal control mechanism is positioned to be latched to the instrument sterile adapter. The transition section <NUM> may hold the surgical instrument in place to allow for preparation of the instrument prior to latching to the instrument sterile adapter. The latch arm structure of the instrument sterile adapter is shown at the point where elastic deformation of the latch arm structure is about to begin.

Referring to <FIG>, the proximal control mechanism is being attached to the instrument sterile adapter. As the proximal control mechanism is pushed toward the instrument sterile adapter, the second angled latch surface <NUM> pushes on the instrument latch arm <NUM> and bends it away from the fixed instrument latch structure. The instrument latch arm <NUM> is sufficiently flexible to pass over the fixed locking surface in the surgical instrument. This allows the instrument latch arm <NUM> to pass over the second locking surface <NUM>.

Referring to <FIG>, the proximal control mechanism is moved toward the instrument sterile adapter until the second locking surface <NUM> enters the instrument latch receiver <NUM> and the instrument latch arm resumes an original undeformed shape to engage the second fixed locking surface. The instrument latch arm <NUM> closes in on the fixed instrument latch structure of the proximal control mechanism, securing the proximal control mechanism to the instrument sterile adapter. In some embodiments, the instrument latch arms <NUM> may be shaped and/or spaced such that when the instrument latch arms <NUM> are closed on the fixed instrument latch structure, the instrument latch arms are bent slightly outward compared to their natural undeformed shape so that they apply inward forces on the fixed instrument latch structure to better secure the proximal control mechanism to the instrument sterile adapter. Securing the proximal control mechanism to the instrument sterile adapter may prevent the carriage latch arm <NUM> and the connecting member <NUM> from moving away from the first locking surface <NUM>, thus providing an interlock of the attachment of the instrument sterile adapter to the instrument carriage.

Referring to <FIG>, a latch release that includes a latch arm engaging portion <NUM> may be used to release the instrument latch arm <NUM> from the second locking surface <NUM>. It will be appreciated that when the instrument sterile adapter is coupled to the instrument carriage and the proximal control mechanism is coupled to the instrument sterile adapter, the entire latch arm structure is enclosed in the instrument carriage and the proximal control mechanism. Therefore it is necessary to provide a mechanism for applying an outward force on the instrument latch arm <NUM> to release the proximal control mechanism from the instrument sterile adapter and allow removal of the surgical instrument.

Referring to <FIG>, the proximal control mechanism <NUM> includes a pair of latch release members 905A, 905B. <FIG> shows a perspective view of a single latch release member <NUM>. Each latch release member <NUM> includes a button portion <NUM> and a latch arm engaging portion <NUM>. As can be seen in <FIG>, two identical latch release members 905A, 905B may be assembled opposite each other on the base of the proximal control mechanism <NUM>. When inward forces are applied to button portions <NUM> of the pair of latch release members 905A, 905B, the pair of latch release members are pushed inward and closer to each other, and the latch arm engaging portions 915A, 915B move outward to apply an outward force on the instrument latch arms <NUM> to release the proximal control mechanism from the instrument sterile adapter and allow removal of the surgical instrument as shown in <FIG>. After the surgical instrument is removed, the instrument sterile adapter <NUM> may be removed from the instrument carriage <NUM> as described above.

Since it is necessary to provide a mechanism for applying an outward force on the instrument latch arm <NUM> to release the proximal control mechanism from the instrument sterile adapter and allow removal of the surgical instrument, it is desirable to provide a backup mechanism for applying an outward force on the instrument latch arm in case the primary mechanism is unavailable for any reason.

Referring to <FIG>, a perspective view of the proximal control mechanism <NUM> of a surgical instrument is illustrated. The surface of the proximal control mechanism that directly engages the instrument sterile adapter is shown. Two release channels <NUM> provide a backup surgical instrument release mechanism in the event that the latch release members <NUM> cannot be used to release the proximal control mechanism. The release channels <NUM> allow a release tool access to the instrument latch arms <NUM> when the proximal control mechanism <NUM> is attached to the instrument sterile adapter. The release tool may be a rigid, slender, and elongate tool, such as an Allen wrench.

Referring further to <FIG>, illustrations of the operation of the backup release mechanism are shown. <FIG> is a perspective view of a proximal control mechanism <NUM> of a surgical instrument attached to an instrument sterile adapter <NUM>. <FIG> is detail cross-sectional of the circled portion of <FIG> taken along the section line <NUM>-<NUM>.

Claim 1:
A method for attaching a surgical instrument to an instrument carriage, the method comprising:
engaging an instrument sterile adapter (<NUM>) with an instrument carriage (<NUM>) using a first latch mechanism (<NUM>) of the instrument sterile adapter; and
engaging a surgical instrument (<NUM>) with the instrument sterile adapter using a second latch mechanism (<NUM>) of the instrument sterile adapter,
wherein in an engaged state of the second latch mechanism with the surgical instrument the first latch mechanism is not disengageable from the instrument carriage, and
wherein the first latch mechanism and the second latch mechanism are coupled to a frame portion (<NUM>, <NUM>) of the instrument sterile adapter via a connecting member (<NUM>).