Patent Description:
Robotic surgical systems have been used in minimally invasive medical procedures. Some robotic surgical systems include a console supporting a surgical robotic arm and a surgical instrument mounted to the robotic arm. The surgical instrument may have an elongated shaft that supports at least one end effector (e.g., forceps or a grasping tool) on a distal end thereof. In some robotic surgical systems, the entire length of the elongated shaft of the surgical instrument must pass through a holder or other feature of the robotic arm, thereby making removal or exchange of the surgical instrument from the robotic arm cumbersome.

Manually-operated surgical instruments often include a handle assembly for actuating the functions of the surgical instrument; however, when using a robotic surgical system, no handle assembly is typically present to actuate the functions of the end effector. It is the robotic arm of the robotic surgical system that provides mechanical power to the surgical instrument for its operation and movement. Each robotic arm may include an instrument drive unit that is operatively connected to the surgical instrument by an interface. The interface couples the selected surgical instrument to the robotic surgical system for driving operations of the surgical instrument and to provide structure for ready removal or exchange of the surgical instrument from the robotic arm. <CIT> and <CIT> refer to prior art relevant for the present invention.

During a surgical procedure, some portions of the surgical instrument may be exposed to a non-sterile environment or non-sterile components. Such exposure may contaminate the surgical instrument, or portions thereof. Since it is imperative that many of the components of the robotic surgical system remain sterile, there is a need to maintain sterility at the interface used to couple the surgical instrument to the robotic surgical system for protecting sterile components of the robotic surgical system from being contaminated by the non-sterile portions of the surgical instrument. A need also exists for a robotic surgical system that enables more efficient and expeditious removal or exchange of a surgical instrument and which has improved usability.

The present invention is defined by appended claim <NUM>. Methods are presently not claimed. In accordance with the present invention, a sterile interface module for coupling an electromechanical robotic surgical instrument to a robotic surgical assembly is provided. The sterile interface module includes a body member, a decoupling collar, and a drive transfer assembly. The body member is configured to selectively couple the surgical instrument to the robotic surgical assembly. The decoupling collar is supported on the body member and is movable relative to the body member from a first position to a second position. The drive transfer assembly is supported by the body member and includes a drive coupler and a transfer shaft extending from the drive coupler. The drive coupler is engagable with the robotic surgical assembly and the transfer shaft is engagable with the surgical instrument. The drive coupler is configured to engage the robotic surgical assembly while the decoupling collar is in the first position to enable the robotic surgical assembly to robotically control the surgical instrument. The drive coupler is retracted within the body member while the decoupling collar is in the second position to prevent the drive coupler from engaging the robotic surgical assembly.

The sterile interface module further includes a locking plate and a locking tab. The locking plate is coupled to the decoupling collar. The locking tab extends from the body member and may be selectively engagable with the locking plate to prevent the decoupling collar from moving from the second position to the first position. The locking plate is movable with the decoupling collar.

In certain embodiments, the sterile interface module may further include a release ring supported on the body member. The release ring may be positioned to prevent the decoupling collar from moving from the first position to the second position. The release ring may be selectively removable from the body member to enable the decoupling collar to move from the first position to the second position. The release ring may seal the body member.

In some embodiments, the sterile interface module may further include an electrical connector supported on the body member. The electrical connector may be configured to enable electrical communication between the robotic surgical assembly and the surgical instrument. Movement of the decoupling collar from the first position to the second position may prevent the electrical connector from providing electrical communication between the robotic surgical assembly and the surgical instrument. The electrical connector may be recessed within the body member.

In certain embodiments, the body member may define a vent.

In some embodiments, the body member may include a pair of nubs that selectively couple to the robotic surgical assembly to secure the body member to the robotic surgical assembly.

According to yet another aspect of the present disclosure, a robotic surgical system is provided. The robotic surgical system includes a surgical instrument including an end effector, a robotic surgical assembly, and a sterile interface module. The sterile interface module may be positionable between the robotic surgical assembly and the surgical instrument to couple the surgical instrument to the robotic surgical assembly.

In some embodiments, the sterile interface module may include nubs that selectively couple to the robotic surgical assembly to secure the sterile interface module to the robotic surgical assembly. The robotic surgical assembly may include buttons that face in the same direction and are depressible to decouple the nubs of the sterile interface module from the robotic surgical assembly so that the sterile interface module releases from the robotic surgical assembly.

In certain embodiments, the robotic surgical system may include a reset cam supported in the sterile interface module and configured to selectively reset the sterile interface module after the decoupling collar is moved from the first position toward the second position.

Other aspects, features, and advantages will be apparent from the description, the drawings, and the claims that follow.

The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the disclosure and, together with a general description of the disclosure given above, and the detailed description given below, serve to explain the principles of the disclosure, wherein:.

Embodiments of the present disclosure are described in detail with reference to the drawings, in which like reference numerals designate identical or corresponding elements in each of the several views. As used herein, the term "distal" refers to that portion of the robotic surgical system, surgical assembly, or component thereof, that is closer to a patient, while the term "proximal" refers to that portion of the robotic surgical system, surgical assembly, or component thereof, that is farther from the patient.

As used herein, the term "clinician" refers to a doctor, nurse, or other care provider and may include support personnel. In the following description, well-known functions or construction are not described in detail to avoid obscuring the present disclosure in unnecessary detail.

Referring initially to <FIG>, a surgical system, such as, for example, a robotic surgical system <NUM>, generally includes one or more surgical robotic arms <NUM>, <NUM>, a control device <NUM>, and an operating console <NUM> coupled with control device <NUM>. Any of the surgical robotic arms <NUM>, <NUM> may have a robotic surgical assembly <NUM> and an electromechanical surgical instrument <NUM> coupled thereto. The robotic surgical assembly <NUM> further includes an instrument drive unit <NUM> and a collar assembly or sterile interface module <NUM> that couples the electromechanical surgical instrument <NUM> to the instrument drive unit <NUM> as described in greater detail below. In some embodiments, the robotic surgical assembly <NUM> may be removably attached to a slide rail <NUM> of one of the surgical robotic arms <NUM>, <NUM>. In certain embodiments, the robotic surgical assembly <NUM> may be fixedly attached to the slide rail <NUM> of one of the surgical robotic arms <NUM>, <NUM>.

Operating console <NUM> includes a display device <NUM>, which is set up to display three-dimensional images; and manual input devices <NUM>, <NUM>, by means of which a clinician (not shown), is able to telemanipulate the robotic arms <NUM>, <NUM> in a first operating mode, as known in principle to a person skilled in the art. Each of the robotic arms <NUM>, <NUM> may be composed of any number of members, which may be connected through joints. The robotic arms <NUM>, <NUM> may be driven by electric drives (not shown) that are connected to control device <NUM>. The control device <NUM> (e.g., a computer) is set up to activate the drives, for example, by means of a computer program, in such a way that the robotic arms <NUM>, <NUM>, the attached robotic surgical assembly <NUM>, and thus the electromechanical surgical instrument <NUM> (including an electromechanical end effector 60a thereof) execute a desired movement according to a movement defined by means of the manual input devices <NUM>, <NUM>. The control device <NUM> may also be set up in such a way that it regulates the movement of the robotic arms <NUM>, <NUM> and/or of the drives.

The robotic surgical system <NUM> is configured for use on a patient "P" positioned (e.g., lying) on a surgical table "ST" to be treated in a minimally invasive manner by means of a surgical instrument such as the electromechanical surgical instrument <NUM>. The robotic surgical system <NUM> may also include more than two robotic arms <NUM>, <NUM>, the additional robotic arms likewise connected to the control device <NUM> and telemanipulatable by means of the operating console <NUM>. A surgical instrument, for example, the electromechanical surgical instrument <NUM>, may also be attached to any additional robotic arm(s).

The control device <NUM> may control one or more motors, e.g., motors (Motor <NUM>. n), each motor configured to drive movement of the robotic arms <NUM>, <NUM> in any number of directions. Further, the control device <NUM> may control the instrument drive unit <NUM> including a motor assembly <NUM> thereof that drives various operations of the end effector 60a of the electromechanical surgical instrument <NUM>. The motor assembly <NUM> of the robotic surgical assembly <NUM> includes any number of motors 74a, 74b, 74c, etc. that couple to the sterile interface module <NUM> via a corresponding number of motor couplers <NUM> such as motor couplers 76a, 76b, 76c, etc. extending from the motors 74a, 74b, 74c, etc..

In general, the robotic surgical assembly <NUM> transfers power and actuation forces (e.g., torque) from the motors 76a, 76b, 76c, etc. of the motor assembly <NUM>, through the sterile interface module <NUM>, to driven members 62a, 62b, 62c, etc. supported within an instrument housing <NUM> of the electromechanical surgical instrument <NUM>. Such transfer of power and actuation forces ultimately drives movement of components of the end effector 60a of the electromechanical surgical instrument <NUM> for operating the electromechanical surgical instrument <NUM>. This movement may include, for example, a movement of a knife blade (not shown) and/or a closing and opening of jaw members (not shown) of the end effector 60a, an articulation/rotation/pitch/yaw of the end effector 60a, and/or the actuation or firing of the end effector 60a (e.g. a stapling portion of the end effector 60a). The driven members 62a, 62b, 62c, etc. of the electromechanical surgical instrument <NUM> are coupled to one or more coupling members "CM" (e.g., cables, drive rods, etc.) at a first end thereof. The one or more coupling members "CM" of the electromechanical surgical instrument <NUM> extend along the electromechanical surgical instrument <NUM> to the end effector 60a of the electromechanical surgical instrument <NUM>. A second end of the one or more coupling members "CM" couples to the end effector 60a of the electromechanical surgical instrument <NUM> for operating the end effector 60a as detailed above. Reference may be made to commonly owned International Patent Application No. <CIT> entitled "Wrist and Jaw Assemblies for Robotic Surgical Systems," <CIT>, or <CIT>, for a detailed discussion of illustrative examples of the construction and operation of end effectors for use with or connection to the electromechanical surgical instrument <NUM>.

The robotic surgical assembly <NUM> may also be configured for the activation or firing of an electrosurgical energy-based instrument or the like, for example, via a drive mechanism (not shown) that may include, for instance, screws/nuts, cable drives, pulleys, friction wheels, rack and pinion arrangements, etc., or combinations thereof.

For a detailed discussion of the construction and operation of a similar robotic surgical system having one or more of the same or similar components for use with one or more components of the presently described robotic surgical system, reference may be made to <CIT>, entitled "Medical Workstation," and/or <CIT>, entitled "Robotic Surgical Assemblies,".

With reference to <FIG>, <FIG>, <FIG>, and <FIG>, the robotic surgical assembly <NUM> of the robotic surgical system <NUM> includes an instrument drive unit or housing <NUM> supporting the sterile interface module <NUM> that couples the electromechanical surgical instrument <NUM> to the instrument drive unit <NUM>. A distal or leading end portion of the instrument drive unit <NUM> includes a pair of buttons 72a, 72b supported adjacent to one another and disposed in the same direction (e.g., front or forward-facing). The buttons 72a, 72b, which are spring biased by one or more springs (not shown) may be simultaneously depressible to attach and/or release the sterile interface module <NUM> to/from the instrument drive unit <NUM>. Each of the buttons 72a, 72b may include one or more protuberances 72c, 72d that are configured to selectively engage with one or more attachment nubs 118a-118d (described in greater detail below) of the sterile interface module <NUM> to selectively secure the sterile interface module <NUM> to the instrument drive unit <NUM>.

For example, with the sterile interface module <NUM> attached to the instrument drive unit <NUM>, depression of the buttons 72a, 72b slides the protuberances 72c, 72d of the respective buttons 72a, 72b relative to the attachment nubs 118a-118d of the sterile interface module <NUM>, as seen in <FIG>. Such relative movement separates the attachment nubs 118a-118d of the sterile interface module <NUM> from the protuberances 72c, 72d of the respective buttons 72a, 72b, whereby the sterile interface module <NUM> can separate from the instrument drive unit <NUM> (e.g., by pulling the sterile interface module <NUM> away from the instrument drive unit <NUM>). Similarly, attachment of the sterile interface module <NUM> can be effectuated by depressing the buttons 72a, 72b so that the attachment nubs 118a-118d of the sterile interface module <NUM> can be inserted adjacent to the one or more protuberances 72c, 72d of the buttons 72a, 72b, whereby release of the depressed buttons 72a, 72b causes the protuberances 72c, 72d to bias into engagement with the respective attachment nubs 118a-118d. Alternatively and/or additionally, the protuberances 72c, 72d and the attachment nubs 118a-118d can be configured to cam along one another such that the sterile interface module <NUM> can be coupled to the instrument drive unit <NUM> via push-in and/or snap-fit connection.

Referring again to <FIG> and <FIG>, the distal end portion of the instrument drive unit <NUM> further supports a ring member <NUM> having a sterile drape <NUM> secured thereto. The ring member <NUM> is secured to the distal end of the instrument drive unit <NUM> via a unilateral axial attachment (e.g., push-in, snap-fit, and/or loose-fit type arrangement), whereby removal of the ring member <NUM> from the instrument drive unit <NUM> may be effectuated laterally (e.g., via sliding and/or rotational movement relative to the instrument drive unit <NUM>). In some embodiments, ring member <NUM> may be supported (e.g., loosely) between the instrument drive unit <NUM> and the sterile interface module <NUM>, and may be trapped between the instrument drive unit <NUM> and the sterile interface module <NUM> until the sterile interface module <NUM> is uncoupled from instrument drive unit <NUM>. The sterile drape <NUM> is configured to overlie the robotic surgical assembly <NUM> and the robotic arms <NUM>, <NUM> and the sterile drape <NUM> may be arranged as desired above about the robotic surgical assembly <NUM> and the robotic arms <NUM>, <NUM> to provide a sterile barrier between the various aforementioned components and/or the surgical site/fluids and the electromechanical surgical instrument <NUM>. Ring member <NUM> is configured to be disposed between the instrument drive unit <NUM> and the sterile interface module <NUM>, and to enable operative interconnection between the instrument drive unit <NUM> and the sterile interface module <NUM>.

Turning now to <FIG>, the sterile interface module <NUM> of the robotic surgical assembly <NUM> is provided for selectively interconnecting the robotic surgical assembly <NUM> and the electromechanical surgical instrument <NUM>. The electromechanical surgical instrument <NUM> may be laterally coupled (e.g., side-loaded) to, or laterally decoupled from, the sterile interface module <NUM> of the robotic surgical assembly <NUM>. In general, the sterile interface module <NUM> functions to provide an interface between the instrument drive unit <NUM> and an electromechanical surgical instrument such as electromechanical surgical instrument <NUM>. This interface advantageously maintains sterility, provides a means to transmit electrical communication between the robotic surgical assembly <NUM> and the electromechanical surgical instrument <NUM>, provides structure configured to transfer rotational force from the robotic surgical assembly <NUM> to the electromechanical surgical instrument <NUM> for performing a function with the electromechanical surgical instrument <NUM>, and/or provides structure to selectively attach/remove the electromechanical surgical instrument <NUM> to/from the robotic surgical assembly <NUM> (e.g., for rapid instrument exchange).

As seen in <FIG>, the sterile interface module <NUM> includes a body member <NUM> having an upper portion 110a, an intermediate portion 110b (<FIG>), and a lower portion 110c that are coupled together by one or more fasteners "F" such as screws 101a, 101b, 101c. The sterile interface module <NUM> includes pins 101d (e.g., pogo pins) (<FIG>) that provide electrically conductive pathways through the sterile interface module <NUM> (e.g., to an end effector 60a of a surgical instrument <NUM> when surgical instrument <NUM> is coupled to the sterile interface module <NUM> - see <FIG>). The upper portion 110a of the body member <NUM> defines drive transfer channels 112a, 112b, 112c, 112d that support drive transfer assemblies <NUM>, such as respective drive transfer assemblies 114a, 114b, 114c, 114d, therein. The upper portion 110a of the body member <NUM> further includes a cover 110z (<FIG>) that defines an electrical connector channel or socket <NUM>. The socket <NUM> enshrouds a first electrical connector 116a (<FIG>) of an electrical assembly 116x (<FIG>) therein. The first electrical connector 116a (e.g., pins thereof), which function as an electrical interface, may be recessed within the socket <NUM> and/or shrouded to protect against damage (e.g., from dropping and/or from mating and/or unmating to the instrument drive unit. The electrical assembly 116x is described in greater detail below.

The sterile interface module <NUM> includes the attachment nubs 118a, 118b, 118c, 118d, which extend around or project from opposed sides of a side wall <NUM> of the upper portion 110a. As detailed herein, the attachment nubs 118a, 118b, 118c, 118d function to selectively couple the sterile interface module <NUM> to the robotic surgical assembly <NUM>. The attachment nubs 118a, 118b, 118c, 118d may have a flag shape to facilitate engagement with the buttons 72a, 72b of the instrument drive unit <NUM>. Each of the attachment nubs 118a, 118b, 118c, 118d includes a head 118e having a tapered cam surface 118f and a lip <NUM> that cooperate with the buttons 72a, 72b (see <FIG>) of the instrument drive unit <NUM> to selectively couple the sterile interface module <NUM> to the instrument drive unit <NUM>.

The upper portion 110a of the body member <NUM> further defines a distally oriented tapered wall or surface <NUM>, which may be helical, and which extends around the upper portion 110a from a shoulder 122a of the upper portion 110a.

With reference to <FIG>, the intermediate portion 110b of the body member <NUM> includes resilient tabs <NUM> extending proximally therefrom. The tabs <NUM>, which may include any number of tabs <NUM>, are disposed in spaced-apart relation to one another and may be disposed in circumferential relation about a longitudinal axis "X" defined through the sterile interface module <NUM> (e.g., four tabs <NUM> separated by <NUM> degree intervals). The tabs <NUM> may be formed of a flexible material and may be configured to flex radially outward. Each of the tabs <NUM> includes a shaft 113a extending proximally to a head 113b. The head 113b of each respective tab <NUM> includes an angled cam surface 113c that extends to a transverse lip 113d.

The intermediate portion 110b of the body member <NUM> movably supports a decoupling collar <NUM> thereon and removably supports an emergency release ring <NUM> thereon. The release ring <NUM> may function to provide fluid and/or dust resistance and/or sealing for the body member <NUM>. In some embodiments, the release ring <NUM> may provide hermetic sealing.

With reference again to <FIG>, the decoupling collar <NUM> defines a tapered ramp 124a that extends from a shoulder 124b of the decoupling collar <NUM>. The tapered ramp 124a of the decoupling collar <NUM> and the shoulder 124b of the decoupling collar <NUM> complement the tapered wall <NUM> and the shoulder 122a of the upper portion 110a of the body member <NUM>.

The decoupling collar <NUM> further includes scallops or gripping grooves 124c about an outer surface thereof to facilitate user gripping and/or movement of the decoupling collar <NUM> relative to the body member <NUM> of the sterile interface module <NUM>. For example, as described in greater detail below, the decoupling collar <NUM> may be rotatable (and/or axially translatable) relative to the body member <NUM>, as indicated by arrow "A", after the release ring <NUM> is removed from the body member <NUM>. Each gripping groove 124c may include a flat 124x (<FIG>) such that the decoupling collar <NUM> includes an array of flats 124x about the outer surface of the decoupling collar <NUM> that further facilitate gripping and/or movement of the decoupling collar <NUM>.

The decoupling collar <NUM> further defines a flange channel 124d (<FIG>) on an inner surface thereof. The decoupling collar <NUM> may also include any number of vents 124e for cooling one or more electrical components of sterile interface module <NUM> and/or instrument drive unit <NUM>. In particular, rotation or activation of a cooling fan (not shown) of instrument drive unit <NUM>, for example, may draw external air internally into the sterile interface module <NUM> through the vents 124e of sterile interface module <NUM> so that the air can travel along one or more air flow pathways (see air flow pathways "AA" and "AB" illustrated in <FIG>) that extend through sterile interface module <NUM> and/or instrument drive unit <NUM>, thereby cooling electrical components thereof as the air travels therealong. Alternatively, and/or additionally, air internally disposed in sterile interface module <NUM> and/or instrument drive unit <NUM> (e.g., hot air generated from operation of the electrical components thereof) can be externally discharged from the vents 124e, for instance, as the cooling fan is activated or rotated (e.g., which generates a compression force that causes the air to be externally discharged).

As illustrated in <FIG>, the release ring <NUM> of the sterile interface module <NUM> includes a body portion 126a defining one or more separation slots 126b, and one or more tabs 126c that extend from the body portion 126a. Each separation slot 126b may be disposed adjacent to frangible segment 126d of the body portion 126a. The frangible segment 126d is configured to break upon a movement of one of the one or more tabs 126c relative to the body portion 126a of the release ring <NUM> so that the release ring <NUM> can be separated from the sterile interface module <NUM> to enable the decoupling collar <NUM> to move relative to the body member <NUM> of the sterile interface module <NUM>.

As illustrated in <FIG>, the lower portion 110c of the body member <NUM> is in the form of a semi-annular coupling cuff that is supported on or otherwise secured to a distal end of the intermediate portion 110b of the body member <NUM>. The lower portion 110c of the body member <NUM> includes a U-shaped body having an instrument opening <NUM> defined between side arms 128a, 128b and opening distally and laterally. The lower portion 110c further includes a ramped surface 128c formed on an inner surface thereof that complements ramped camming surfaces 61a, 61b (<FIG>) disposed on an outer surface of the instrument housing <NUM> of the electromechanical surgical instrument <NUM>. The instrument opening <NUM> is configured to receive an electromechanical surgical instrument, such as electromechanical surgical instrument <NUM>, therein to removably secure the electromechanical surgical instrument <NUM> to the robotic surgical assembly <NUM>. The side arms 128a, 128b of the lower portion 110c extend distally from the intermediate portion 110b of the body member <NUM> and are positioned to support the electromechanical surgical instrument <NUM> within the instrument opening <NUM> of the lower portion 110c.

As seen in <FIG>, the sterile interface module <NUM> further includes a floating plate <NUM> supported between the intermediate portion 110b of the body member <NUM> and the lower portion 110c of the body member <NUM>. The floating plate <NUM> of the sterile interface module <NUM> is movable between an uncompressed position or extended position and a compressed or retracted position. The floating plate <NUM> is spring biased distally toward the uncompressed position biasing members of the drive transfer assemblies 114a, 114b, 114c, 114d (<FIG>) of the sterile interface module <NUM>. In some embodiments, by a round spring (e.g., a wave spring) or the like (not shown) may be used to distally bias the floating plate <NUM> to the uncompressed position. The floating plate <NUM> includes a base portion <NUM> and tabs 134a, 134b extending distally from the base portion <NUM>. The tabs 134a, 134b of the floating plate <NUM> extend through the lower portion 110c of the body member <NUM>. The floating plate <NUM> defines apertures <NUM> therein that receive the drive transfer assemblies 114a, 114b, 114c, 114d of the sterile interface module <NUM>. The floating plate <NUM> may function to prevent perpendicular loads acting on the drive transfer assemblies 114a, 114b, 114c, 114d, for example, upon a side loading of an electrosurgical instrument to the sterile interface module <NUM>.

As seen in <FIG> and <FIG>, the sterile interface module <NUM> further includes a support plate <NUM> coupled to the decoupling collar <NUM>. The support plate <NUM> defines coupling openings 123a in registration with the drive assemblies <NUM> of the sterile interface module <NUM>, and tab apertures 123b in registration with the tabs <NUM> of the intermediate portion 110b of the sterile interface module <NUM>. The tab apertures 123b may be configured to impart a radial inward flex on the tabs <NUM> (e.g., the shafts 113a of the tabs <NUM>) as the angled cam surfaces 113c of the heads 113b of the tabs <NUM> cam along the tab apertures 123b of the support plate <NUM>, as detailed below. The support plate <NUM> includes a flange 123c that is received within the flange channel 124d of the decoupling collar <NUM> to enable the support plate <NUM> to move with the decoupling collar <NUM>.

The sterile interface module <NUM> further includes a ring coupler <NUM> coupled to the decoupling collar <NUM> and in contact with a bottom surface of the flange 123c of the support plate <NUM> so that the decoupling collar <NUM> can rotate around the flange 123c of the support plate <NUM>, as indicated by arrow "A" (<FIG>), while axially moving the support plate <NUM> as the rotation of the decoupling collar <NUM> axially translates the decoupling collar <NUM> relative to the longitudinal axis "X," as indicated by arrow "B1. " The decoupling collar <NUM> may be axially moveable relative to the body member <NUM> without rotation, as indicated by arrow "B2" (<FIG>).

As seen in <FIG>, the ring coupler <NUM> includes a ledge 125a that extends radially inward from the ring coupler <NUM> along at least a portion of a circumference of the ring coupler <NUM> to support idler coupler <NUM>. With reference also to <FIG>, the ring coupler <NUM> further includes a transverse cross-section having a tapered profile 125b along at least portions of the ring coupler <NUM>. For example, the ring coupler <NUM> may include a tapered profile 125b adjacent to one or more of the vents 124e of the decoupling collar <NUM>. The tapered profile 125b may be positioned in fluid communication with one or more of the vents 124e to provide one or more air flow pathways, such as air flow pathways "AA" and "AB" illustrated in <FIG>, between the ring coupler <NUM> and the decoupling collar <NUM>.

The air flow pathways "AA" and "AB" function to aid in maintaining component sterility and cooling various components (e.g., motors, sensors, etc.) of the robotic surgical system <NUM> (e.g., the sterile interface module <NUM>, instrument drive unit <NUM>, etc.) The air flow pathways provide a balanced cross-sectional area of air flow from outside the sterile interface module and into the instrument drive unit for cooling and thermal management. The air flow pathways provide a tortuous path for air flow through the sterile interface module and into the instrument drive unit. Vents may be shaped to a desired symbology such as loading or unloading direction use of arrows. Symbology may be molded in and/or laser etched and positioned for instructional indicia pertaining to use, loading, removal, mating and/or warnings.

With reference to <FIG>, the sterile interface module <NUM> also includes an idler coupler <NUM> that is coupled to the ring coupler <NUM> and supported on the ledge 125a of the ring coupler <NUM>. The idler coupler <NUM> is rotatably supported on a coupling shaft <NUM> that interconnects the upper and intermediate portions 110a, 110b of the body member <NUM>. The idler coupler <NUM> is axially slidable along the coupling shaft <NUM> as the decoupling collar <NUM> rotates about the longitudinal axis "X" and/or axially moves relative to the body member <NUM>, as detailed herein.

With reference to <FIG> and <FIG>, each of the drive transfer assemblies <NUM> of the sterile interface module <NUM> includes a drive coupler <NUM> defining a coupling end 115a (e.g., a slot) engagable with one of the respective motor couplers <NUM> of the motor assembly <NUM> on a proximal end of the drive coupler <NUM>. Drive coupler <NUM> further includes a flange 115b on a distal end thereof. Each drive coupler <NUM> extends through one of the coupling openings 123a of the support plate <NUM> of the sterile interface module <NUM>. The support plate <NUM> is coupled to the decoupling collar <NUM> so that a bottom surface of the support plate <NUM> is in contact with a top surface of the flange 115b of the drive couplers <NUM> of the drive transfer assemblies <NUM>. Each of the drive transfer assemblies <NUM> includes a first transfer shaft <NUM> or a second transfer shaft <NUM>. The first transfer shaft <NUM> includes a radial coupler 117a extending radially outward from the transfer shaft <NUM>, and a distal coupler 117b extending distally from the transfer shaft <NUM>. The second transfer shaft <NUM> includes a distal coupler 119a that extends distally from the transfer shaft <NUM>. The distal couplers 117b and 119a of the respective first and second transfer shafts <NUM>, <NUM> are configured to engage corresponding couplers (not shown) of the driven members 62a, 62b, 62c, etc. of the electromechanical surgical instrument <NUM>. Any of the couplers described herein may be in the form of a gear having any number of teeth.

Each of the drive transfer assemblies <NUM> of the sterile interface module <NUM> includes a spring <NUM> to enable components of the respective drive transfer assemblies <NUM> to move relative to one another. As seen in <FIG> and <FIG>, for example, a first spring 121a is supported between the first transfer shaft <NUM> and its respective drive coupler <NUM>, and a second spring 121b is supported between the second transfer shaft <NUM> and its respective drive coupler <NUM>. Each spring <NUM> is configured to apply spring force to its respective drive transfer assembly <NUM> upon compression thereof.

As seen in <FIG> and <FIG>, the sterile interface module <NUM> includes an electrical assembly 116x including the first electrical connector 116a, a second electrical connector 116b, and an electrical ribbon 116c coupled between the first and second electrical connectors 116a, 116b to provide electrical communication between the robotic surgical assembly <NUM> and any electromechanical surgical instrument, such as electromechanical surgical instrument <NUM>, coupled thereto. The electrical assembly 116x may include a counter (not shown) configured to measure use of the sterile interface module <NUM>, for example, to account for degradation of spring pins 116d of one or both of the electrical connectors 116a, 116b over time such that the sterile interface module <NUM> can be replaced as necessary or desired.

With reference to <FIG>, <FIG> and <FIG>, to couple an electromechanical surgical instrument, such as electromechanical surgical instruments <NUM>, to the sterile interface module <NUM>, the ramped camming surfaces 61a, 61b of the electrosurgical instrument <NUM> are aligned with the ramped surface 128c of the lower portion 110c of the sterile interface module <NUM>. The electromechanical surgical instrument <NUM> is then transversely moved (e.g., side loaded) relative to the robotic surgical assembly <NUM> until the ramped camming surfaces 61a, 61b of the electromechanical surgical instrument <NUM> are fully received or seated on the ramp surface 128c of the lower portion 110c of the sterile interface module <NUM>.

As the electromechanical surgical instrument <NUM> is transversely moved into the lower portion 110c of the sterile interface module <NUM>, the electromechanical surgical instrument <NUM> cams upwardly to proximally move or compress the floating plate <NUM> of the sterile interface module <NUM> relative to the body member <NUM>, as indicated by arrows "C" shown in <FIG> (see also <FIG>. Movement of the floating plate <NUM> from its initial extended position (<FIG>) into a compressed position (<FIG>) draws the transfer shafts <NUM>, <NUM> (and their corresponding instrument engagement ends 117b, 119a) of the sterile interface module <NUM> proximally away from the instrument opening <NUM> of the lower portion 110c of the sterile interface module <NUM> to facilitate insertion of the electromechanical surgical instrument <NUM> into the instrument opening <NUM> of the sterile interface module <NUM>. Moving the floating plate <NUM> from the extended position (<FIG>) to the compressed position (<FIG>) helps prevent insertion contact/interference between the distal couplers 117b, 119a of the drive transfer assemblies <NUM> of the sterile interface module <NUM> and corresponding driven members 62a, 62b, 62c, etc. of the electromechanical surgical instrument <NUM> (see <FIG>).

Once the electromechanical surgical instrument <NUM> is fully seated within the lower portion 110c of the sterile interface module <NUM>, the floating plate <NUM> of the sterile interface module <NUM> is urged back to the extended position (<FIG>) so that the distal couplers 117b, 119a of the drive transfer assemblies <NUM> of the sterile interface module <NUM> and the corresponding driven members 62a, 62b, 62c, etc. of the electromechanical surgical instrument <NUM> come into registration with one another to couple the electromechanical surgical instrument <NUM> to the robotic surgical assembly <NUM> via the sterile interface module <NUM>.

With the robotic surgical assembly <NUM> of the robotic surgical system <NUM> secured to one of the surgical robotic arms <NUM>, <NUM>, of the robotic surgical system <NUM>, and the electromechanical surgical instrument <NUM> of the robotic surgical system <NUM> secured to the sterile interface module <NUM> of the robotic surgical system <NUM>, a clinician can perform a surgical procedure by robotically controlling the driven members 62a, 62b, 62c, etc. of the electromechanical surgical instrument <NUM> with the motor assembly <NUM> of robotic surgical assembly <NUM> as desired. In particular, one or more of the motors 76a, 76b, 76c, etc. of the motor assembly <NUM> are actuated to rotate one or more of the motor couplers 76a, 76b, 76c, etc. of the of the motor assembly <NUM> so that one or more of the drive transfer assemblies <NUM> of the sterile interface module <NUM> cooperate with one or more of the driven members 62a, 62b, 62c, etc. of the electromechanical surgical instrument <NUM> to operate and/or manipulate the end effector 60a of the electromechanical surgical instrument <NUM> as desired (e.g., fire, articulate, rotate, etc.).

To remove the electromechanical surgical instrument <NUM> from the robotic surgical assembly <NUM>, for example, to perform an instrument exchange, a clinician can depress paddles 64a, 64b of the electromechanical surgical instrument <NUM> (<FIG>). Depression of the paddles 64a, 64b imparts a force on tabs 130a, 130b (<FIG>) of the floating plate <NUM> of the sterile interface module <NUM> to move the floating plate <NUM> in a proximal direction relative to the body member <NUM> of the sterile interface module <NUM>. As the floating plate <NUM> moves in a proximal direction, the first and second transfer shafts <NUM>, <NUM> of the respective drive transfer assemblies <NUM> translate with the floating plate <NUM> of the sterile interface module <NUM> in the proximal direction against biasing forces from the springs <NUM> of the respective drive transfer assemblies <NUM>. Movement of the transfer shafts <NUM>, <NUM> of the respective drive transfer assemblies <NUM>, <NUM> relative to the body member <NUM> of the sterile interface module <NUM> separates the distal couplers 117b, 119a of the first and second transfer shafts <NUM>, <NUM> of the drive transfer assemblies <NUM> from the respective driven members 62a, 62b, 62c, etc. of the electromechanical surgical instrument <NUM>.

Once the distal couplers 117b, 119a of the first and second transfer shafts <NUM>, <NUM> of the respective drive transfer assemblies <NUM> are separated from the respective driven members 62a, 62b, 62c, etc. of the electromechanical surgical instrument <NUM>, the proximal end of the instrument housing <NUM> of the electromechanical surgical instrument <NUM> can be slid laterally out from the instrument opening <NUM> of the lower portion 110c of the body member <NUM> of the sterile interface module <NUM>.

The electromechanical surgical instrument <NUM> can be re-attached to the sterile interface module <NUM> through the instrument opening <NUM> of the lower portion 110c of the body member <NUM> of the sterile interface module <NUM> as described above. Alternatively, a different electromechanical surgical instrument (e.g., a stapler, endoscope, forceps, etc.) can be likewise attached as desired.

With reference to <FIG>, <FIG>, in an emergency situation such as when there is an electrical power failure, and when the electromechanical surgical instrument <NUM> is at least partially positioned within a patient, the release ring <NUM> of the sterile interface module <NUM> can be removed from the body member <NUM> of the sterile interface module <NUM>. With respect to <FIG>, the tabs 126c of the release ring <NUM> can be manually manipulated relative to the body portion 126a of the release ring <NUM> until the frangible segment 126d of the release ring <NUM> breaks so that the release ring <NUM> can be separated from the sterile interface module <NUM>.

With reference to <FIG>, once the release ring <NUM> is separated from the sterile interface module <NUM>, the decoupling collar <NUM> of the sterile interface module <NUM> can be rotated about the body member <NUM> of the sterile interface module <NUM>, as indicated by arrow "A," to move the decoupling collar <NUM> axially in the distal direction from an initial, proximal-most position toward the lower portion 110c of the body member <NUM> of the sterile interface module <NUM>. In effect, such movement of the decoupling collar <NUM> enables the sterile interface module <NUM> to provide a manual override function. In the initial, proximal-most position of the decoupling collar <NUM> (<FIG>), the ring and idler couplers <NUM>, <NUM> of the sterile interface module <NUM> are longitudinally spaced from the radial coupler 117a of the first transfer shaft <NUM> of the sterile interface module <NUM>.

The decoupling collar <NUM> of the sterile interface module <NUM> can be moved (e.g., rotationally and/or axially) from the initial, proximal-most position (<FIG>) to a distal-most position (<FIG>) through any number of intermediate positions between the proximal-most and distal-most positions. Rotation of the decoupling collar <NUM> of the sterile interface module <NUM> (from the proximal-most toward the distal-most position), rotates the ring coupler <NUM> of the sterile interface module <NUM>, which causes the idler coupler <NUM> of the sterile interface module <NUM> to freely rotate about, and/or distally slide along the coupling shaft <NUM> of the sterile interface module <NUM>.

Continued distal advancement of the idler coupler <NUM> of the sterile interface module <NUM>, in response to the continued distal movement (e.g., rotational and/or axial movement) of the decoupling collar <NUM> of the sterile interface module <NUM> relative to the body member <NUM> thereof, causes the idler coupler <NUM> to engage with the radial coupler 117a of the first transfer shaft <NUM> of one of the drive assemblies <NUM> of the sterile interface module <NUM>. As the decoupling collar <NUM> advances distally, the decoupling collar <NUM> draws the support plate <NUM> of the sterile interface module <NUM> distally relative to the tabs <NUM> of the sterile interface module <NUM> so that the heads 113b of the tabs <NUM> slide through the tab apertures 123b of the support plate <NUM>. The angled cam surface 113c of the heads 113b of the tabs <NUM> cam along the tab apertures 123b as the support plate <NUM> moves relative to the tabs <NUM>. Distal advancement of the support plate <NUM> also draws the drive couplers <NUM> of the drive assemblies <NUM> distally by virtue of contact between the bottom surface of the support plate <NUM> and the top surface of the flanges 115b of the drive couplers <NUM> (<FIG> and <FIG>). Distal movement of the drive couplers <NUM> separates the coupling ends 115a of the drive couplers <NUM> from the respective motor couplers <NUM> of the motor assembly <NUM> of the robotic surgical assembly <NUM> and retracts the drive couplers <NUM> of the sterile interface module <NUM> within the drive transfer channels 112a, 112b, 112c, 112d of the body member <NUM> of the sterile interface module <NUM>.

Once the support plate <NUM> of the sterile interface module <NUM> is moved distally past the angled cam surfaces 113c of the tabs <NUM> of the sterile interface module <NUM>, the tabs <NUM> flex outwardly (in response to inward flexing resulting from contact between the heads 113b of the tabs <NUM> and the tab apertures 123a of the support plate <NUM>) so that transverse lips 113d of the tabs <NUM> extend over a top surface of the support plate <NUM> and prevent the support plate <NUM> from moving proximally (see <FIG>). In this distal-most position of the support plate <NUM> and the decoupling collar <NUM> of the sterile interface module <NUM>, the decoupling collar <NUM> and the drive couplers <NUM> of the drive assemblies <NUM> are also prevented from moving proximally such that the drive couplers <NUM> cannot reengage with the motor couplers <NUM> of the motor assembly <NUM>, preventing robotic control of the drive couplers <NUM>.

The distal movement of the decoupling collar <NUM> of the sterile interface module <NUM> toward this distal-most position may electrically disconnect one or more of electrical connectors 116a, 116b and/or the electrical ribbon 116c of the sterile interface module <NUM> so that there is no electrical communication between the robotic surgical assembly <NUM> and the electromechanical surgical instrument <NUM>. For example, the electrical ribbon 116c may be secured to the support plate <NUM> such that the distal advancement of the decoupling collar <NUM> relative to the body member <NUM> of the sterile interface module <NUM> separates the electrical ribbon 116c from the electrical connector 116a.

Once the decoupling collar <NUM> of the sterile interface module <NUM> is disposed in the distal-most position, rotation of the decoupling collar <NUM> causes the ring coupler <NUM> to rotate the idler coupler <NUM> of the sterile interface module <NUM>. With the idler coupler <NUM> engaged with the radial coupler 117a of the first transfer shaft <NUM> of the sterile interface module <NUM>, rotation of the idler coupler <NUM> rotates the radial coupler 117a and thereby rotates the distal coupler 117b of the first transfer shaft <NUM>. This rotation of the transfer shaft <NUM> may be independent of the second transfer shafts <NUM> of the sterile interface module <NUM> (which may generally remain stationary without robotic control thereof). As the distal coupler 117b of the first transfer shaft <NUM> rotates in response to rotation of the idler coupler <NUM>, the distal coupler 117b of the first transfer shaft <NUM> cooperates with a respective one of the driven members 62a, 62b, 62c, etc. of the electromechanical surgical instrument <NUM> to advantageously manually manipulate the end effector 60a thereof.

Such movement of the decoupling collar <NUM> of the sterile interface module <NUM> from the proximal-most position to the distal-most position, imparts forces (e.g., torque) through the respective components of the sterile interface module <NUM> and the electromechanical surgical instrument <NUM> to manually manipulate the end effector 60a of the electromechanical surgical instrument <NUM> to position the end effector 60a in a desired orientation/position. For example, the end effector 60a of the electromechanical surgical instrument <NUM> can be manually manipulated to an open position to release tissue grasped by the end effector 60a so that the electromechanical surgical instrument <NUM> can be removed from a surgical site while limiting the risks of undesirable tissue damage that would otherwise be present if such manual manipulation were not feasible when a power failure or other similar emergency situation arises. It is also contemplated that the decoupling collar <NUM> of the sterile interface module <NUM> can be rotated in the opposite direction as desired to manipulate (e.g., close) the end effector 60a of the electromechanical surgical instrument <NUM>.

With the release ring <NUM> of the sterile interface module <NUM> removed and the decoupling collar <NUM> fixed in the distal-most position via the fixed or locking relationship between the tabs <NUM> and support plate <NUM> of the sterile interface module <NUM>, the sterile interface module <NUM> can no longer robotically control any electromechanical surgical instrument coupled thereto such that removal and replacement of the sterile interface module <NUM> is required. As described above, the sterile interface module <NUM> can be removed from the robotic surgical assembly <NUM> by depressing the buttons 72a, 72b of the sterile interface module <NUM>. A replacement sterile interface module <NUM> and electromechanical surgical instrument <NUM> can then be attached as detailed above to enable robotic control of any electrosurgical instrument coupled to the robotic surgical assembly <NUM> as detailed herein.

Turning now to <FIG>, one embodiment of sterile interface module system, generally referred to as <NUM>, includes a sterile interface module <NUM> defining a longitudinal axis "X-X" and a reset tool <NUM>. The sterile interface module <NUM> is similar to the sterile interface module <NUM> and includes a body member <NUM> that supports a reset cam <NUM> and a release ring <NUM>. The body member <NUM> of the sterile interface module <NUM> supports a decoupling collar <NUM> and includes tabs <NUM> that cooperate with the reset cam <NUM>. The body member <NUM> of the sterile interface module <NUM> defines pull tab recesses <NUM> and lock slots <NUM> therein that cooperate with the release ring <NUM>.

Advantageously, the reset tool <NUM> of the sterile interface module system <NUM> cooperates with the reset cam <NUM> of the sterile interface module <NUM> of the sterile interface module system <NUM> to enable the sterile interface module <NUM> to be activated, tested, and reset during the manufacturing assembly and qualification of the sterile interface module <NUM>.

As seen in <FIG> and <FIG>, the reset cam <NUM> of sterile interface module <NUM> is supported about the tabs <NUM> of sterile interface module <NUM> and includes arms <NUM> that extend radially outward from the reset cam <NUM> at spaced apart locations about reset cam <NUM>. Each arm <NUM> of the reset cam <NUM> defines a receiving aperture 312a therethrough that receives a respective one of the tabs <NUM> of the sterile interface module <NUM>. The reset cam <NUM> further defines a central opening <NUM> configured to receive the reset tool <NUM>. The reset cam <NUM> may include threading 314a about central opening <NUM> to facilitate threaded engagement with reset tool <NUM>. In some embodiments, the reset cam <NUM> may include a self-tapping feature, boss, and/or a detent feature (not shown) to engage reset tool <NUM>. The reset cam <NUM> may be formed of any suitable plastic and/or metallic material.

With reference to <FIG>, the release ring <NUM> of the sterile interface module <NUM> includes an annular frame <NUM> having a first end portion <NUM> and a second end portion <NUM> that are selectively engagable (e.g., so that release ring <NUM> is resettable). The annular frame <NUM> of the release ring <NUM> supports pull tabs 358a, 358b on opposed sides of the annular frame <NUM> (e.g., for ease of access) that extend distally from the annular frame <NUM> and which include a distal taper configuration that recess pull tabs 358a, 358b within the pull tab recesses <NUM> (<FIG>) of the sterile interface module <NUM> to help prevent false activation. The pull tabs 358a, 358b of the release ring <NUM> may be finger width to provide leverage assist for actuation. An inner surface of the annular frame <NUM> includes a plurality of radial tabs <NUM> that extend radially inward to provide concentric alignment with the body member <NUM> of the sterile interface module <NUM> and assist in preventing false activation of the release ring <NUM> from the body member <NUM> of the sterile interface module <NUM>. A top surface of the annular frame <NUM> of the release ring <NUM> supports locking tabs 362a, 362b that extend proximally therefrom and are aligned with the pull tabs 358a, 358b of the release ring <NUM>. The locking tabs 362a, 362b are receivable within the lock slots <NUM> of the sterile interface module <NUM>. The locking tabs 362a, 362b function to align the pull tabs 358a, 358b and to prevent false activation of the release ring <NUM>.

The first end portion <NUM> of the annular frame <NUM> of the release ring <NUM> defines a receiving slot 354a and the second end portion <NUM> of the annular frame <NUM> includes a protuberance 356a. The protuberance 356a of the second end portion <NUM> of the annular frame <NUM> is receivable within the receiving slot 354a of the first end portion <NUM>, for example, via snap-fit, interference-fit or the like to provide optimal separation force for a finger activation, and which can be reset multiple times for disassembly during cleaning, for example.

The first end portion <NUM> of the annular frame <NUM> further includes first and second arms 354d, 354e having spaced-apart tabs 354b that extend between the first and second arms 354d, 354e. The tabs 354b define separate openings 354c at spaced-apart locations between the first and second arms 354d, 354e of the first end portion <NUM>. Advantageously, the release ring <NUM> of the sterile interface module <NUM> provides a moisture barrier to prevent moisture ingress into the sterile interface module <NUM>. The release ring <NUM> may be provided in any suitable highly contrasting or bright color, such as orange or red, to help communicate its presence for prompt removal. The release ring <NUM> can include any suitable indicia such as molded in symbols or text to indicate its purpose as an emergency release. The release ring <NUM> can be manufactured in any form of a high elongation plastic, elastomer, or flexible material that is conducive for cleaning and sterilization.

With reference to <FIG> and <FIG>, in use, the release ring <NUM> of the sterile interface module <NUM> is removed by finger actuating one or both of the pull tabs 358a, 358b of the release ring <NUM> with sufficient force to separate or uncouple the first and second end portions <NUM>, <NUM> of the release ring <NUM> so that the release ring <NUM> can be unraveled from around the sterile interface module <NUM> (<FIG>). The decoupling collar <NUM> of the sterile interface module <NUM> can then be rotated (e.g., counterclockwise) and translated downward about the body member <NUM> of the sterile interface module <NUM>, as indicated by arrows "M1" and "M2," for example, to test and/or qualify the sterile interface module <NUM> (<FIG>). As the decoupling collar <NUM> rotates and translates downward, the support plate <NUM> of the sterile interface module <NUM> cams along the tabs <NUM> of the sterile interface module <NUM> until the tabs <NUM> extend radially outward over the support plate <NUM> and prevent the support plate <NUM> from moving proximally toward its initial position (e.g., lockout the support plate <NUM>).

Referring to <FIG>, to reset the sterile interface module <NUM>, the reset tool <NUM> can be inserted into a central opening 301a defined in the body member <NUM> of the sterile interface module <NUM> and advanced into engagement with the reset cam <NUM>. The reset tool <NUM> can then be manipulated (e.g., rotated) relative to the sterile interface module <NUM>, as indicated by arrows "R," to cause the reset cam <NUM> to advance axially upwards along the tabs <NUM> of the body member <NUM> of the sterile interface module <NUM>, as indicated by arrow "U. " As the reset cam <NUM> cams along the tabs <NUM>, the reset cam <NUM> approximates the tabs <NUM> towards one another in a radial inward direction, as indicated by arrows "RI," until the support plate <NUM> of the sterile interface module <NUM> can be moved proximally (e.g., translation and/or clockwise rotation of the decoupling collar <NUM>) to its initial proximal position (see <FIG>) where the support plate <NUM> is proximal to the tabs <NUM> of the sterile interface module <NUM> to reset the sterile interface module <NUM>. Once the support plate <NUM> is in its proximal position, the reset tool <NUM> can be removed from the sterile interface module <NUM>. The release ring <NUM> of the sterile interface module <NUM>, or a new release ring <NUM>, can then be reattached about the body member <NUM> of the sterile interface module <NUM> so that the sterile interface module <NUM> can be used in a surgical procedure.

The robotic surgical system <NUM> and/or components thereof (e.g., the robotic surgical assembly <NUM>, the sterile interface module <NUM>, <NUM> etc.) may include one or more electrical components (e.g., electrically coupled to electrical assembly 116x) that function to provide sterile interface module identification. For example, these electrical components may include one or more of the following: a contact (which may be an insulated and/or non-insulated contact), a sensor, a magnetic array, a Hall sensor, a Reed switch, a wireless feature, an optical feature, a bar code, a QR code, etc., and/or combinations thereof (not shown), where any of number and/or configuration of each these electrical components may be provided.

Any of the presently disclosed electrical components may function to provide the following for the presently disclosed sterile interface modules and/or as a feed through recognition for a device, instrument, and/or reload unit for one or more of the following: serial number, lot code and/or date code of manufacturing, device type, end of life, calibration date and offsets, reload type, usage and/or number of uses, device status, instrument stroke position, clamp position, wrist position, rotation angle, pitch and/or yaw position, knife and/or cutting mechanism position, energy activation, RF activation, cautery activation, harmonic vibration activation, end effector type, end effector status, end effector position, end effector end of life and/or use status, and/or combinations thereof.

In embodiments, the presently disclosed sterile interface modules can be provided in various configurations, for example, to facilitate manual override functions similar to that described above. For instance, embodiments of sterile interface modules, or components thereof, such as the decoupling collar <NUM>, can be configured to drive and/or operate one or more drives, drive one unique drive, and/or can be rotated clockwise, counterclockwise, and/or combinations thereof. In some embodiments, the decoupling collar <NUM> can be configured to rotate in a single desired direction.

In certain embodiments, the presently disclosed sterile interface modules, or components thereof (e.g., decoupling collar <NUM>, release ring <NUM>, <NUM>, etc.) can include external ribbing, grooves, texture, etc. to improve manual grasping capability.

In certain embodiments, decoupling one of the presently disclosed sterile interface modules from the drive motor coupler of the instrument drive unit eliminates backdrive loading and reduces the possibility of a seized motor, coupler or gear set or drive within the instrument drive unit.

In some aspects, one failure mode of the instrument drive unit <NUM> may include a condition in which one or more motors 76a, 76b, 76c, etc. thereof are in a fault state (e.g., cannot applying torque to the drive components of robotic surgical assembly <NUM> and/or electromechanical surgical instrument <NUM>). In certain aspects, another failure mode may include a condition in which one or more motors 76a, 76b, 76c, etc. of instrument drive unit <NUM> are unable to rotate. In such aspects, it may be necessary to decouple couplers of the sterile interface module <NUM> from couplers of the instrument drive unit <NUM> (e.g., via downward motion) to enable a clinician to spin one or more couplers of the sterile interface module <NUM> irrespective of a position of corresponding couplers of the instrument drive unit <NUM>. This minimizes the torque needed to rotate the couplers of the sterile interface module <NUM> by eliminating the need to back drive the motor. Ramp features of the decoupling collar <NUM> of sterile interface module <NUM> may aid in such decoupling effort (e.g., the downward motion) and provide a mechanical advantage to lower the force needed to act (e.g., pull down) on the collar <NUM> by helping provide break-away force needed to overcome initial friction due to engagement of the couplers of robotic surgical assembly <NUM> and/or electromechanical surgical instrument <NUM> and the transmission of torque through the interface thereof.

In some embodiments, the decoupling collar may have a diameter that provides large leverage torque for the end user.

In certain embodiments, the presently disclosed sterile interface modules, or components thereof, may include a combination of plastics, or plastics and metals, to eliminate the need for lubrication that can be removed during cleaning and sterilization processes. Plastic materials of the presently disclosed sterile interface module may be produced with high impact and elongation rating plastics that may also be rated for high temperatures and chemical resistance. These materials of the presently disclosed sterile interface module may be specified to provide robust designs for the medical auto washers, autoclave steam sterilization cycling, impact/collisions mild drops and/or abuse during use, and for central processing and cleaning. In some embodiments, materials of the presently disclosed sterile interface module may be high temperature, noncorrosive and/or conducive for autoclaving and/or autowashing. These materials can include, but are not limited to, stainless steel, polyphenylsulfone plastics, PEEK, PPSU (Radel), PSU, PES, Ultem, PAEK, and the like, or combinations thereof. In embodiments, flexible portions of electronics of the presently disclosed sterile interface modules can be mechanically separated, disconnected, or shorted to prevent electronic communication and reuse after activation.

In some embodiments, the presently disclosed sterile interface modules, or components thereof, can include dielectric Insulation, for example, plastics, coatings, films and high dielectric materials can be incorporated to provide a dielectric barrier between the instruments/devices and the instrument drive unit. In certain embodiments, one or more couplers may include a non-conductive plastic to increase the dielectric strength of the interface to coupled devices. In some embodiments, ribs, tongue and grooves, dovetail joints, flanges and/or overlapping walls can be incorporated to increase creepage and clearance dielectric performance.

In some embodiments, the presently disclosed sterile interface modules, or components thereof, can include sealing features. For example, one or more seals can be incorporated to increase fluid resistance and to prevent egress/ingress, one or more seals can be incorporated around the outer diameter of the proximal or distal ends of the couplers, one or more gaskets can be used on the proximal and distal mating faces for sealing, and/or one or more gaskets can be incorporated around the proximal or distal connector interface that compress when mated to the instrument drive unit or instrument.

In certain embodiments, the presently disclosed sterile interface modules, or components thereof, can include side load rail mating features. For example, the presently disclosed sterile interface module, or components thereof, can include lead in features for ease of mating, ribs for locking, dual actuators to prevent false activation, and/or spring loaded plate locking features that lock devices and eliminate play and/or movement of the interface.

In certain embodiments, the presently disclosed sterile interface module, or components thereof, can include one or more wedged surfaces on mounting latches thereof, for example, to eliminate or reduce the mated play/clearances.

In some embodiments, the presently disclosed sterile interface modules, or components thereof, can include cleaning and/or sterilization features. For example, the presently disclosed sterile interface modules, or components thereof, can be configured to be flushable and cleanable to ease cleaning and sterilization. In embodiments, the presently disclosed sterile interface modules, or components thereof, can include a flush port for ease of cleaning. In some embodiments, the presently disclosed sterile interface module, or components thereof, may be disposable and/or adapted for single use.

In embodiments, one or more of the couplers may be Oldham type couplers that allow for full coupling through high levels of tolerance and misalignment. Any of the presently disclosed couplers may include one or more teeth or other similar coupling features.

According to some embodiments, one or more actuators (e.g., two actuators) may be utilized for instrument drive unit mounting to resist false activation during automated usage, collisions, and or by an end user. Actuators may include sub flush, high throw actuators to prevent false actuation.

In some embodiments, one or more couplers can include angular faces that clutch out after attaining a threshold torque. The clutch may be bi directional and/or unidirectional. In embodiments, the clutch torque thresholds can be different values for clockwise and/or counterclockwise rotation.

In some embodiments, the presently disclosed sterile interface modules, or components thereof, can include backlash reduction features. For example, teeth of other similar mating feature of one or more of the couplers may include angled faces which may mate under spring loading. Angled faces may provide ample mating during blind mate conditions and/or can eliminate or reduce backlash when such angled surfaces act as a hard stop for the respective coupler.

In certain embodiments, the presently disclosed sterile interface modules, or components thereof, can include coupler bearings including, but not limited to, integral journal, sleeve, ball, radial, thrust, and/or needle type.

In some embodiments, the presently disclosed sterile interface modules, or components thereof, can include axially floating couplers. For example, axial floating couplers may be configured to float axially on one or both coupling interfaces. Such axial floating couplers may utilize compression, extension, leaf, wave springs and/or elastomers. In embodiments, the floating plate may retain the couplers and act as a thrust bearing surface to simultaneously disengage all couplers in unison.

Mounting features of the presently disclosed sterile interface modules for facilitating mounting thereof may include, but are not limited to, latches, threads, sliders and/or clips.

Electronic features of the presently disclosed sterile interface modules may include coatings and/or potting materials to improve autoclaving and/or autowashing resistance. Such coatings and/or potting materials may include, but are not limited to, humiseal, parylene, and/or silicones. Wires of the electronic features may utilize high temp jacket materials such as Teflon, Teflon blends, and/or silicones. Flex circuit materials of the electronic features may include polyimides for high temperature resistance. These wire and/or flex materials may be provided for a high flex cycle life conduit for the presently disclosed floating interface assemblies.

Turning now to <FIG> and <FIG>, one embodiment of a floating plate assembly, generally referred to as <NUM>, includes the floating plate <NUM> and a bus bar <NUM> mounted thereon. The floating plate <NUM> of the floating plate assembly <NUM> supports pogo pins 101d that are coupled together via the bus bar <NUM>. The bus bar <NUM> may be in the form of a conductive plate that electrically couples the pogo pins 101d and/or mechanically captures or supports the pogo pins 101d within the floating plate <NUM>. The bus bar <NUM> defines spaced-apart openings <NUM>, <NUM> that receive tips <NUM> of the pogo pins 101d therein. The bus bar <NUM> may include any suitable flexible material such as a flex printed circuit board (PCB). In some embodiments, the bus bar <NUM> may include any suitable rigid material such as a rigid PCB. In certain embodiments, the bus bar <NUM> can be coated with any suitable material such as silicone and/or epoxy. For example, such coating may function to protect the bus bar <NUM> during an autoclaving and/or cleaning process. In certain embodiments, the bus bar <NUM> may include metal. The bus bar <NUM> may have any suitable plating to protect against corrosion.

Claim 1:
A sterile interface module for coupling an electromechanical robotic surgical instrument to a robotic surgical assembly, the sterile interface module comprising:
a body member configured to selectively couple the surgical instrument to the robotic surgical assembly;
a decoupling collar supported on the body member and movable relative to the body member from a first position to a second position; and
a drive transfer assembly supported by the body member and including a drive coupler and a transfer shaft extending from the drive coupler, the drive coupler engagable with the robotic surgical assembly and the transfer shaft engagable with the surgical instrument, the drive coupler configured to engage the robotic surgical assembly while the decoupling collar is in the first position to enable the robotic surgical assembly to robotically control the surgical instrument, the drive coupler retracted within the body member while the decoupling collar is in the second position to prevent the drive coupler from engaging the robotic surgical assembly; characterized in , further comprising:
a locking plate coupled to the decoupling collar; and
a locking tab extending from the body member and selectively engagable with the locking plate to prevent the decoupling collar from moving from the second position to the first position wherein the locking plate is movable with the decoupling collar.