Patent ID: 12186048

In the drawings, the first digit in a three-digit reference numeral of an element is the number of the figure in which that element first appears.

DETAILED DESCRIPTION

In one aspect, management of a drape sleeve305of a sterile surgical drape is enhanced by attaching drape sleeve305to insertion assembly135using an attachment element325. This effectively divides a drape sleeve into two parts—a first pocket part305aand a second pocket part305b(FIGS.3A and3B); i.e., the single tube of drape sleeve305is subdivided into a plurality of tubes. In this aspect, drape sleeve305extends from a mechanical interface element350around surgical instrument manipulator assembly140and around insertion assembly135to a portion of a rotatable seal mounted on entry guide manipulator assembly platform132.

In the system ofFIG.2, drape sleeve205was managed as a whole as a surgical instrument manipulator assembly was moved distally (e.g., moved in a first direction) and proximally (e.g., moved in a second direction opposite to the first direction). In contrast, configuring sleeve305to have a plurality of pocket parts makes management of sleeve305easier and reduces the likelihood that sleeve305is caught or snagged as surgical instrument manipulator assembly140is moved in the first and second directions.

Instead of managing one rather long tube, as inFIG.2, the management problem is reduced to managing a plurality of shorter tubes. Shorter tubes make it easier for excess sleeve material to accordion as the tube length shortens instead of possibly bowing out and contacting a part of insertion assembly135or some other part of the surgical system.

In the examples ofFIGS.3A and3B, at least one sleeve of a plurality of sleeves of a surgical system drape is subdivided into two pocket parts by attaching the or each sleeve to an insertion assembly associated with that sleeve. The attachment point to insertion assembly135is selected so that that the attachment does not result in sleeve305being caught or snagged by insertion assembly135at the location of the attachment, and so that the proximal and distal movement of insertion assembly135is not hindered by the attachment.

The subdivision of drape sleeve305into two pocket parts is illustrative only and is not intended to be limiting. In other aspects, drape sleeve305can be subdivided into more than two pocket parts by using more than one attachment location on insertion assembly135. The number of pocket parts in plurality of pocket parts is selected to facilitate surgical drape sleeve management.

In another aspect, to further facilitate management of a drape sleeve405, a drape shroud assembly420(FIGS.4A and4B) is mounted on an insertion assembly135of computer assisted surgical system100to create a medical device insertion assembly. In this aspect, drape sleeve405extends from a mechanical interface element450around surgical instrument manipulator assembly140, around drape shroud assembly420, and around insertion assembly135to a portion of a rotatable seal. Unlike, the prior system illustrated inFIG.2, as surgical instrument manipulator assembly140is moved distally and proximally by insertion assembly135(i.e., moved in the first direction and in the second direction), drape shroud assembly420prevents drape sleeve405from being entangled in the mechanism of insertion assembly135. This assures not only the integrity of the sterile barrier, it also assures that the surgical procedure is not hampered by drape sleeve405being caught in insertion assembly135.

In one aspect, drape shroud assembly420is mounted to insertion assembly135. A distal portion of insertion assembly135is at least partially surrounded by drape shroud assembly420. Enough of insertion assembly135is surrounded by drape shroud assembly420so that drape shroud assembly420prevents drape sleeve405from interacting with the distal portion of insertion assembly135as insertion assembly135moves surgical instrument manipulator assembly140in a proximal direction and in a distal direction. In one aspect, drape shroud assembly420has a shape that prevents drape sleeve405from interacting with any part of insertion assembly135.

In one aspect, drape sleeve405is affixed to drape shroud assembly420at a drape tie-down region425so that drape sleeve405is divided into a first drape sleeve portion405aand a second drape sleeve portion405b. The division of drape sleeve into two separate portions, sometimes called pockets, alleviates the bulk that must be collapsed and extended as surgical instrument manipulator assembly140is moved proximally and distally by insertion assembly135. Thus, further reduces the likelihood that drape sleeve405becomes entangled in insertion assembly135.

In this example, drape shroud assembly420includes a body having a first end and a second end. An outer surface of the body of drape shroud assembly420extends between the first end and the second end. An inner surface of the body of drape shroud assembly420also extends between the first end and the second end. The inner surface of the body bounds an inner volume. The inner volume is sized to permit at least part of insertion assembly135to be contained within the inner volume, and the body is configured for attachment to the insertion assembly135. In one aspect, a plurality of tabs extend from the second end of the body. A drape attachment region of drape shroud assembly420is defined, in one aspect, by an indentation in the outer surface of the body.

To further consider the aspects of a drape shroud assembly,FIG.5Aillustrates one insertion assembly535suitable for use with drape shroud assembly520(FIG.5B). Insertion assembly535is a telescoping insertion assembly that includes a frame530, a mid-carriage536, and a distal carriage538. Mid-carriage536rides on a ball screw531in frame530. In one aspect, ball screw531has a 6 mm pitch and so is back-drivable. Mid-carriage536includes a metal belt537that drives distal carriage538. Distal carriage538is attached to a housing of a surgical instrument manipulator assembly. In one aspect, distal carriage538moves twice as far as mid-carriage536.

Frame530and ball screw531together are an example of a first portion of an insertion assembly. Mid-carriage536and distal carriage538are an examples of a second portion and a third portion, respectively, of insertion assembly535.

FIG.5Bshows drape shroud assembly520affixed to insertion assembly535. In this aspect, drape shroud assembly520is attached to a middle portion of insertion assembly535(i.e., mid-carriage536) by screws. In more general terms for dividing a drape sleeve into two pockets with a telescoping assembly having a plurality of portions, the drape shroud assembly is attached to a middle portion of the plurality of portions. This divides the drape sleeve into two more manageable length pockets.

A first end520-1of a body524of drape shroud assembly520is adjacent a first end (distal end) of mid-carriage536. Body524of drape shroud assembly520extends in a second direction (proximally) from first end along mid-carriage536to a second end (proximal end)520-2. The first and second directions are shown by arrow590.

Extending from second end520-2of body524of drape shroud assembly520is a plurality of tabs521. Plurality of tabs521, in one aspect, includes three tabs that are a part of drape shroud assembly520. The number of tabs in plurality of tabs521and the size of individual tabs are selected so that as insertion assembly535retracts into the base, plurality of tabs521does not interfere with the nesting of insertion assembly535or with other parts in the base. If there is not an interference problem, the proximal end of drape shroud assembly520can be solid. The size and shape of each of plurality of tabs521help guide the sleeve of the surgical drape around frame530as insertion assembly535moves in the first and second directions (i.e., moves in distal and proximal directions) as represented by arrow590.

Drape shroud assembly520includes an inner volume that is bounded by the inner surface of the body of drape shroud assembly520. As distal carriage538is moved towards a most proximal position, which was referred to above as the fully withdrawn position, distal carriage538and mid-carriage536slide by frame530, and so drape shroud assembly520surrounds frame530such that frame530is in the inner volume of drape shroud assembly520.

Adjacent second end520-2of body524of drape shroud assembly520is a drape tie-down region525. This region helps identify where the sleeve of the surgical drape should be secured to drape shroud assembly520so that appropriately sized sub-pockets are formed in the surgical drape to facilitate automatic drape management as insertion assembly535moves proximally and distally. In one aspect, drape tie-down region525is an indented region in body524of drape shroud assembly520. Alternatively, drape tie-down region525could be identified in various ways, such as with a differently colored region of body524, two lines on the outer surface of body524, a different surface texture, or any combination of such features.

The vertical length of drape shroud assembly520is selected so that when insertion assembly535is in the fully withdrawn position, none of plurality of tabs521and second end520-2contact either the rotatable part of the rotatable seal to which the drape sleeve is attached or contact entry guide manipulator assembly133, but drape shroud assembly520prevents the sleeve of the surgical drape from being snagged or engaged by entry guide manipulator assembly133.

FIGS.6A,6B,6C, and6Dare more detailed illustrations of one example of an insertion assembly635, a drape shroud assembly620, and a surgical instrument manipulator assembly640. Insertion assembly635is the same as insertion assembly535, and so includes a frame630with a ball screw upon which mid-carriage536is mounted. Belt637in mid-carriage636drives a distal carriage to which the housing of surgical instrument manipulator assembly640is attached. Drape shroud assembly620is attached to mid-carriage636in the same way as described above for drape shroud assembly520.

Insertion manipulator640includes a housing that is attached to the distal carriage of insertion assembly635. The housing of insertion assembly640includes an insertion assembly guard645that forms a part of the housing of surgical instrument manipulator assembly640. Insertion assembly guard645extends from the side of the housing to which the distal carriage of insertion assembly635is attached, and partially surrounds a portion of insertion assembly635. An inner surface of insertion assembly guard645in combination with the wall of the housing of surgical instrument manipulator assembly640that abuts insertion assembly635defines an opening646that surrounds both drape shroud assembly620and insertion assembly635, when insertion assembly635is in the fully extended position. In addition, when insertion assembly635is in the fully retracted position, insertion assembly guard645keeps the distal end of the drape sleeve open so that drape shroud assembly620does not snag the drape sleeve.

In one aspect, surgical instrument manipulator assembly640includes a drive unit and a drive output assembly. The drive output assembly is coupled to the drive unit. The drive output assembly includes a low backlash coupler coupled to the drive unit. A drive output disk is coupled to the low backlash coupler.

A sterile adapter650(FIG.6A), which is a mechanical interface element, is mounted on the distal face of surgical instrument manipulator assembly640. A boot of a sterile surgical drape, for example boot763-1of sterile surgical drape760, is affixed to sterile adapter650and extends in the proximal direction around the housing of surgical instrument manipulator assembly640. (An illustration of an example of a sterile surgical drape760is presented inFIG.7.) The boot of the sterile surgical drape, in one aspect, extends to the proximal end of surgical instrument manipulator assembly640and around the housing including insertion assembly guard645. A sleeve of the sterile surgical drape is affixed to a proximal end of the boot and extends from the proximal end of the boot to a rotatable part of the rotatable seal. The sleeve of the sterile surgical drape is attached to drape tie-down region625of drape shroud assembly620using a tie-down.

In one aspect, during assembly of the surgical drape, a template is used to position a polyester strap on the drape sleeve, and the polyester strap is attached to the drape sleeve using double-sided pressure-sensitive tape. The polyester strap has hook and loop fabric attached to it so that the size of the polyester strap can be adjusted as necessary to strap the drape sleeve to drape tie-down region625. An example of hook fabric and loop fabric is a nylon fastening tape consisting of two strips of nylon fabric, one having tiny hooked threads and the other having a coarse looped surface. The two strips form a strong bond when pressed together. One example of a commercially available fastening tape is VELCRO® fastening tape. (VELCRO® is a registered trademark of Velcro Industries B.V.)

FIGS.6C and6Dare opposing oblique side views of the proximal portion of drape shroud assembly620.FIGS.6C and6Dillustrate one example of plurality of tabs621-1,621-2,621-3extending in the proximal direction from proximal end620-2of body624of drape shroud assembly620.

In one embodiment, surgical drape760includes a first portion761(FIG.7) configured to cover platform132, links113,115,117, and119, and the associated joints. First portion761includes an exterior sterile surface and an interior surface. The interior surface is configured to be positioned adjacent to platform132, links113,115,117, and119, and the associated joints. First portion761is affixed to a stationary portion of rotatable seal765, such as a roll cover portion of a rotatable labyrinth seal.

A second portion762of surgical drape760includes a plurality of drape sleeves762-1to762-4(drape sleeves762-3, and762-4are not visible inFIG.7), with each drape pocket including at a distal end a boot and a sterile adapter (only boots763-1,763-2and sterile adapters764-1,764-2are visible inFIG.7). Each sterile adapter includes a mechanical interface configured to mate between the instrument mount interface of a respective surgical instrument manipulator assembly and the input interface of the transmission unit of the corresponding surgical instrument.

A rotating portion of rotatable seal765, such as a base comb portion of a rotating labyrinth seal, is coupled to a proximal opening of each of plurality of drape sleeves762-1to762-4to allow all of the drape sleeves to rotate together as a group with reference to more proximal first portion761of surgical drape760. See U.S. Patent Application Publication No. US 2011/0277775 A1 for an example of a suitable surgical drape and rotatable seal.

In one aspect, first portion of761of surgical drape760and the plurality of drape sleeves are made of a polyethylene material such as ethylene methyl acrylate, commonly referred to as “EMA.” In one aspect, each of the plurality of boots is made from low-density polyethylene (LDPE).

As used herein, “first”, “second”, “third”, etc. are adjectives used to distinguish between different components or elements. Thus “first”, “second”, and “third” are not intended to imply any ordering of the components or elements or to imply any total number of components or elements.

The above description and the accompanying drawings that illustrate aspects and embodiments of the present inventions should not be taken as limiting—the claims define the protected inventions. Various mechanical, compositional, structural, electrical, and operational changes may be made without departing from the spirit and scope of this description and the claims. In some instances, well-known circuits, structures, and techniques have not been shown or described in detail to avoid obscuring the invention.

Further, this description's terminology is not intended to limit the invention. For example, spatially relative terms—such as “beneath”, “below”, “lower”, “above”, “upper”, “proximal”, “distal”, and the like—may be used to describe one element's or feature's relationship to another element or feature as illustrated in the figures. These spatially relative terms are intended to encompass different positions (i.e., locations) and orientations (i.e., rotational placements) of the device in use or operation in addition to the position and orientation shown in the figures. For example, if the device in the figures were turned over, elements described as “below” or “beneath” other elements or features would then be “above” or “over” the other elements or features. Thus, the exemplary term “below” can encompass both positions and orientations of above and below. The device may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein interpreted accordingly. Likewise, descriptions of movement along and around various axes include various special device positions and orientations.

The singular forms “a”, “an”, and “the” are intended to include the plural forms as well, unless the context indicates otherwise. The terms “comprises”, “comprising”, “includes”, and the like 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. Components described as coupled may be electrically or mechanically directly coupled, or they may be indirectly coupled via one or more intermediate components.

All examples and illustrative references are non-limiting and should not be used to limit the claims to specific implementations and embodiments described herein and their equivalents. Any headings are solely for formatting and should not be used to limit the subject matter in any way, because text under one heading may cross reference or apply to text under one or more headings. Finally, in view of this disclosure, particular features described in relation to one aspect or embodiment may be applied to other disclosed aspects or embodiments of the invention, even though not specifically shown in the drawings or described in the text.

Embodiments described above illustrate but do not limit the disclosure. It should also be understood that numerous modifications and variations are possible in accordance with the principles of the present disclosure. For example, in many aspects the devices described herein are used as single-port devices; i.e., all components necessary to complete a surgical procedure enter the body via a single entry port. In some aspects, however, multiple devices and ports may be used.