US20050216038A1 - Apparatus for surgical suturing with thread management - Google Patents

Abstract

An apparatus and a method for surgical suturing with thread management. An apparatus for tissue suturing comprising a cartridge having a suturing needle having a pointed end and a blunt end, the suturing needle capable of rotating about an axis; a pusher assembly comprising a cartridge holder having a needle rotation drive capable of releasably engaging the cartridge and rotating the suturing needle about the axis; and an actuator capable of releasably engaging the needle rotation drive to rotate the needle rotation drive. A method for suturing tissue comprising placing a suturing device having a cartridge containing a suturing needle to span separated tissue segments; activating an actuator to cause rotational movement of the suturing needle through the separated tissue segments; and deactivating the actuator to stop an advancing movement of the suturing needle to cause a suturing material to be pulled through the separated tissue segments forming a stitch.

Description

RELATED APPLICATIONS
• This application is a divisional of application Ser. No. 10/127,254, filed on Apr. 22, 2002, which claims priority to U.S. Provisional Application Ser. No. 60/298,281, filed on Jun. 14, 2001, for “Surgical Suturing Device with Thread Management” by John Meade and Niall Deloughery.
FIELD OF THE INVENTION
• The present invention relates to a surgical device for suturing tissue. More particularly, the present invention relates to a suturing device that enables the manipulation and control of the suturing needle and suturing material during operation, and methods for using such a device for suturing tissue.
BACKGROUND OF THE INVENTION
• Sutures are used in a variety of surgical applications including closing ruptured or incised tissue, soft tissue attachment, anastomosis, attachment of grafts, etc. Conventionally, suturing of ruptured or incised tissues, for example, is accomplished by the surgeon passing the sharpened tip of a curved suturing needle with a suture attached to the opposite blunt end of the needle through the incised tissue segments to be sutured such that the needle tip penetrates the tissue segments causing the needle to span the incision. The needle is then pulled through the tissue segments manually causing the attached suture to follow the curved path of the needle. Usually a knot is tied at the trailing end of the suture to anchor the first stitch. This action is performed repetitively with application of tension to the needle to pull the entire suture through the tissue segments through subsequent stitches until the entire incised segments are sutured together with a plurality of stitches.
• For example, conventional, open abdominal surgery, including OB-Gyn procedures such as Cesarean delivery, creates a substantial incision (typically eight or more inches in length) in the fascia. In major orthopedic surgery, such as total hip replacement, even longer incisions in two layers of fascia must be closed. The closure of fascia must be done carefully at the conclusion of the surgical procedure, prior to skin closure. Closing fascia by hand suturing is a routine, repetitive, and time-consuming procedure. Typical abdominal incisions may take as long as twenty minutes, while in the case of hip replacement surgery, fascia closure can take even longer. Alternative mechanical suturing devices, as well as staplers, bone anchors, and suture-based arterial closure devices have been used as alternatives to hand suturing in other applications, since manual suturing is a tedious and the speed of the procedure is mostly dependent on skill of the surgeon. Moreover, manual suturing involves the handling and manipulation of a sharp suturing needle with an instrument such as a needle forceps, which can result in slipping and inadvertent, accidental needle pricks through a surgeon's or nurse's gloves, posing a potential risk of infection for the surgeon, nurse, staff, and patient. Furthermore, the direct handling of the needle can cause the needle to become contaminated with pathogenic bacteria that can cause onset of infection at the site of the sutures. There is also a risk of the needle penetrating the bowel and causing a serious, and often fatal infection.
• Suturing devices described in the art designed to overcome these limitations are, however, either unduly complex design and economically non-viable or relatively difficult to use and unsuited for precise manipulation for suturing areas that are not easily accessible. For example, the device disclosed in U.S. Pat. No. 4,557,265 has to be held sideways in relation to the direction of the incision being closed. Another limitation of prior art suturing devices is their inability to provide positive control over the needle and suture during the suturing process. This can result in non-uniform sutures with either overly loose or overly tight stitches, which can cause excessive bleeding and risk tearing the repaired tissue in the patient.
• A suturing device that maintains a positive control over the suturing needle and is capable of providing uniform stitches is disclosed in U.S. Pat. Nos. 5,437,681 and 5,540,705. The disclosed device requires a “scissors-like” grip and is operated by the surgeon's thumb that provides articulation of the drive mechanism that causes rotation of a linear drive shaft encased in a barrel, which in turn causes a suturing needle encased in a disposable cartridge mounted at the distal end of the barrel to rotate in an advancing motion through the tissue. The device is, however, limited in its efficient operability in the following ways: (1) the rotational direction of the needle and the drive shaft is in a direction that is perpendicular to the device actuating handles, thereby rendering the device relatively difficult to manipulate and control, (2) does not allow the user to view the needle and its progress through the tissue during the suturing operation, since the barrel containing the drive shaft leading to the needle cartridge does not have an open construction to permit such observation, because the action of the needle is blocked from user's view by the nature of the instrument design, thereby making it difficult for the user to position the advancing needle with high accuracy along the junction of the incised tissue segments and (3) the rate of needle advancement and, therefore, the size and uniformity of the stitches is essentially controlled by the user by the extent to which the articulation mechanism is depressed, thereby rendering the process of obtaining uniform needle rotation, tissue penetration and suture advancement difficult and entirely dependent on the skill of the user.
SUMMARY OF THE INVENTION
• The present invention provides a suturing device that closely emulates or replicates the manual suturing actions carried out by a surgeon. The suturing device of the present invention provides greater ease of use and allows better visualization for the user during its operation than present mechanical suturing methods, while maintaining control over needle movement, advancement and suturing thread management during all phases of the suturing process, thereby preventing entanglement of the suturing thread material during needle movement.
• A benefit provided the suturing device of the present invention is that it enables maneuvering a suturing material through a tissue incision in a manner substantially similar to the way a surgeon would do so by hand. In particular, the suturing device first pushes a suturing needle from the tail of the needle and drives the point of the needle through the tissue. The device then picks up the point of the needle after it has been driven through the tissue, and pulls the remainder of the suturing needle and the suture attached to the suturing needle through the tissue. The suturing needle thus consistently follows the arc of its own curve, which is the preferred method of suturing, in the most non-traumatic way of passing a needle through tissue. A benefit provided by the suturing device of the present invention is the ability of the suturing needle to pull the suturing thread entirely through the tissue segments being closed, following each stitch. The present invention also relates to a suturing device comprising a suturing needle that is protected by a housing cartridge, whereby the suturing needle is not exposed to or handled directly by the user, thereby precluding inadvertent needle sticks. The configuration of the suturing device of the present invention also protects against inadvertent penetration of a bowel by the needle, since the cartridge acts as a shield between the bowel and the needle.
• The suturing needle of the present invention is configured to fit into a cartridge, which in turn, is removably attached to the distal end of the suturing device. The present invention further provides an actuating means and a shaft and drive assembly that provides a torquing force to the suturing needle to cause the needle to advance through tissue during a suturing process without inadvertent retraction.
• The suturing device of the present invention offers several advantages over conventional methods used by surgeons for suturing tissue in that it provides a hand-held suturing instrument of relatively simple mechanical construction and which requires no external motive source. The present invention provides relative ease of operation for the surgeon with only one hand, thereby enabling the surgeon to move obstructing tissue, debris and biological fluids from the suturing site with a free hand, while eliminating the need for needle holders, pick-up forceps, and other tools normally required for suturing by hand. Furthermore, the suturing device of the present invention can be configured as to length, tip, needle, suture, and needle cartridge size for use in conventional open surgery as well as in minimally invasive surgery (MIS) and in “less-invasive” surgery, such as through natural orifices or through small incisions. Additionally, the suturing head can be oriented in any preferred direction and either fixed in a particular orientation, or rendered movable in a variety of orientations by an articulation means.
• These and other advantages of the present invention will be obvious through the embodiments described hereinafter. The present invention accordingly comprises the features of construction, combination of elements and arrangement of parts that will be exemplified in the following detailed description.
• The surgical suturing device of the present invention is configured to provide a “pistol like” grip for the user that includes a barrel assembly and a handgrip that extends from the proximal end of the barrel. The barrel assembly has either a linear or non-linear configuration, including but not limited to, straight, curved and angled configurations. The barrel assembly comprises a plurality of hollow segments capable of being coupled together by one or more universal joints that do not require a permanent connection between the segments, enabling segments to be pulled apart individually and separated. A cartridge holder is removably attached to the distal end of the barrel assembly by a plurality of support arms to which is releasably mounted a disposable cartridge that is capable of accommodating a suturing needle and a suturing thread material.
• The disposable cartridge has a generally cylindrical housing with an aperture in the sidewall of the housing at the distal or working end thereof. An arcuate suturing needle having a sharp, pointed tip at one end of the needle is slidably mounted in a circular track at the distal end of the housing and opposite to the location of the aperture. The needle is connected to a terminal end of a suturing material or thread with a suturing thread source, such as for example, a spool assembly that is contained either entirely within, or remains external the cartridge. The radius of the arc defining the arcuate suturing needle is approximately equal to the circumference to the cartridge housing at the aperture therein. The needle normally resides in a “home” position in its track such that the gap in the arcuate suturing needle is in alignment with the aperture in the cartridge housing. The sharp, pointed end of the needle is situated on one side and entirely within the confines of the housing aperture; the pointed end is, therefore, always shielded by the cartridge housing. The blunt end of the suturing needle that is attached to the suturing thread is located at the opposite side of the aperture. The sharp, pointed end of the needle is, therefore, wholly contained within the cartridge and does not protrude and be exposed to the user.
• In accordance with the present invention, the needle may be releasably engaged by a driving means that is rotatably mounted within the barrel assembly so that the needle can be rotated from its home position by about 360° about the central vertical axis of the cartridge. Such a rotatory action of the needle causes its sharp tip to advance across the cartridge housing so as to span the aperture. Thus, when the device is positioned such that the incised tissue segments to be sutured are situated at the housing aperture, the needle penetrates the tissue segments and spans the incision between them. A continued rotatory movement of the needle causes it to return it to its original “home” position, and thereby causes the suturing thread attached to the needle to be pulled into and through the tissue in an inward direction on one side of the tissue incision, and upwards and out through the tissue on the opposite side of the incision. Thus, the suture follows the curved path of the needle to bind the tissues together with a stitch of thread across the incision in a manner identical to that of a surgeon suturing manually, wherein the needle is “pushed” from the tail and then “pulled” from the point by the drive mechanism. Preferably, an anchoring means is provided at the trailing terminal end of the suturing material to prevent the material from being pulled completely through and out of the tissue segments. For example, the anchoring means can be a pre-tied or a welded loop, a knot wherein the suture is simply tied, or a double-stranded, looped suture is that attached to the suturing needle.
• The rotatory movement of the needle within the needle cartridge is accomplished by a needle driver that may be operated by the user by holding the suturing device with one hand in a pistol-like grip around the handle, and using at least one finger of that hand to activate a triggering lever. The suturing device includes a finger operated trigger lever located proximally to the handle, which when actuated, operates a drive shaft encased within the universal joint barrel assembly through a drive mechanism so as to cause the drive shaft to undergo a rotatory motion, thereby causing the suturing needle to advance in a circular motion. Thus, by placement of the device with the needle cartridge aperture spanning the incised tissue segments and actuating the trigger lever, the suturing device enables the user to lay down a running stitch or interrupted stitch to close the tissue incision in a time efficient manner.
• The needle cartridge of the present invention is disposably mounted on a cartridge holder assembly that is removably attached to the distal end of the universal joint barrel assembly. The cartridge holder assembly is supported by a plurality of support arms that extend from the distal end of the universal joint barrel assembly. The minimalized structural design of the support arms enables the user to have a clear, unobstructed view of the suturing needle as it advances through the tissue segments during the course of a suturing operation, thereby enabling precise placement of the suturing device to provide uniform sutures and precluding the risk of tearing tissue by its placement too close to the edge of the incision. The suturing device of the invention is then advanced a short distance along the incision and the aforementioned operation is repeated to produce another stitch comprising the suturing material. The suturing device of the invention can either pull the entire suture material through the tissues automatically under controlled tension thereby replicating the actions of a surgeon suturing manually so as to tighten the formed stitches without tearing tissue. Alternatively, the surgeon simply pulls the thread by hand to tighten the stitch placed over the incised tissue segments by passage of the suturing needle of the suturing device of the invention.
• The user may continue to manipulate the suturing device, alternately advancing and actuating rotation of the needle about an axis that is generally parallel to the direction of advancement to create a continuous suture which may extend through the entire length of the incision or a series of interrupted stitches. After each individual stitch is laid down, it is tightened by exerting a pull on the suturing material so that the resultant suture is neat and tensioned uniformly along the length of the incised tissue segments. Therefore, a tight closure of the segments is accomplished and bleeding and tearing of tissue are minimized.
• As will be described in greater detail below, the needle driver may be operated by the surgeon holding the instrument with one hand, and using at least one finger of that hand. The suturing device includes a finger-operated lever that is functionally coupled with internal gearing and forms part of a handgrip that is located at one terminal end of the device, that enables the surgeon to efficiently and effectively lay down a running stitch, or a series of interrupted or uninterrupted stitches, to close a tissue incision in a minimum amount of time.
• The suturing device of the present invention can additionally include an associated thread management system, which operates in conjunction with the needle driver to control or handle the suturing material or thread during rotation of the suturing needle. For example, the thread management roller pushes the thread away from the track so the suture does not get pinched by the needle as the needle re-enters the track. Thus, there is minimal probability of the thread becoming tangled or hung up during the suturing operation. The thread management system can also include a mechanism whereby the suturing material or thread is controllably “paid out” during the suturing process.
• When using the suturing device of the present invention, no ancillary instruments or tools such as needle holders, pick-up forceps or the like are needed to complete the suture. Also, the suturing device may be configured in different ways with respect to length and angle of the universal joint barrels, the angle between barrel segments and the number and shape of the support arms. The size of the needle, needle cartridge, cartridge aperture and aperture position may also be varied for use in open surgery to perform procedures such as closing of the fascia, skin closure, soft tissue attachment, anastomosis, fixation of mesh, grafts and other artificial materials. The suturing device or the present invention may also be designed with a very small working end or tip at the end of a long rigid shaft or a flexible shaft that can be oriented in any preferred direction so that the instrument may be used for MIS, such as suturing in the course of endoscopic surgery, including laparoscopy, thoracoscopy and arthroscopy, as well as less-invasive surgical procedures.
• In addition to offering all of the advantages discussed above, the suturing device of the present invention is relatively simple and cost efficient to manufacture. Therefore, the suturing device should find widespread suturing applications that include single stitches or continuous stitches, e.g. spiral, mattress, purse string, etc., that are required to close tissue incisions, attach grafts, or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
• The present invention will be further explained with reference to the attached drawings, wherein like structures are referred to by like numerals throughout the several views. The drawings shown are not necessarily to scale, with emphasis instead generally being placed upon illustrating the principles of the present invention.
• FIG. 1 shows a pictorial view of the suturing device of the present invention including the main components of a cartridge, a cartridge holder assembly, drive shaft segments, a universal coupling joint assembly and a sleeve, an actuator handle with an actuating trigger.
• FIG. 2 shows a sectional view of the shaft-universal joint assembly attached to one embodiment of the suturing device functional end comprising the pusher, cartridge assembly and cartridge operable by a side drive mechanism.
• FIG. 3A shows a segmented sectional view of suturing device functional end comprising a universal joint assembly without and with the universal joint sleeve.FIG. 3B shows an identical view with the universal joint sleeve.
• FIGS. 4A, 4B and4C show enlarged views of a single universal joint, joint coupler and a pair of coupled universal joints respectively.
• FIG. 5 shows an expanded view of the universal joint sleeve configured at a 30° angle.
• FIG. 6 shows a detailed view of one embodiment of a cartridge mount assembly comprising pair of supporting arms and a shaft segment.
• FIGS. 7A and 7B show two different views of one embodiment of the needle cartridge.
• FIGS. 8A and 8B show two embodiments of the curved suturing needle with suture material ports that are operable by a side drive mechanism.
• FIG. 9 shows an expanded view of the thread management roller housed in the cartridge.
• FIG. 10 shows an expanded view of the “anti-rotate” pin housed in the cartridge assembly.
• FIG. 11A shows an expanded view of the pawl.FIG. 11B shows an expanded view of the pusher comprising a cartridge holder support arm with the pawl in place.
• FIG. 12 shows a cut-away segment view showing interaction points of a suturing needle with a cartridge holder and support arm components.
• FIG. 13 shows a segmented view of the relative configuration of a suturing needle with respect to the cartridge holder.
• FIG. 14 shows a segmented sectional view of the functional end of a second embodiment of the suturing device operable by a rear drive mechanism comprising a shaft segment, the pusher, cartridge holder and cartridge (shown sectionally inFIGS. 15-19).
• FIG. 15A shows a perspective view of a pusher with a cartridge holder assembly comprising an attached cartridge with a suture threading mechanism for restraining a suture material.
• FIG. 15B shows a pusher comprising the cartridge holder assembly and a cut-away section of a cartridge comprising the curved suture needle that is operable by a rear drive mechanism.
• FIG. 16 shows an expanded view of a curved suturing needle with suture material port that is operable by a rear drive mechanism.
• FIGS. 17A and 17B show front and rear views of the cartridge.
• FIG. 18 shows a cut-away sectional top view of a pusher comprising a cartridge holder assembly with a locking gate.
• FIGS. 19A, 19B and19C shows the operation of the pusher arm in a cartridge assembly operating in a rear drive mode. The pusher arm traverses radially by opening the gate (FIG. 19A), which springs to the closed position (FIGS. 19B and 19C) after its passage.
• FIGS. 20A, 20B and20C show a three-dimensional, a sectional and a cross-sectional view, respectively, of a ratchet assembly of the present invention that is driven by a drive shaft and activates a pusher arm upon device actuation.
• While the above-identified drawings set forth preferred embodiments of the present invention, other embodiments of the present invention are also contemplated, as noted in the discussion. This disclosure presents illustrative embodiments of the present invention by way of representation and not limitation. Numerous other modifications and embodiments can be devised by those skilled in the art which fall within the scope and sprit of the principles of the present invention.
DETAILED DESCRIPTION
• The suturing device of the present invention is shown generally at1 inFIG. 1. Referring toFIG. 1, the suturing device1 of the present invention can be used to produce a continuous or interrupted stitch or suture so as to enable closure of the segments of an incised tissue. The suturing device1 includes anactuator handle12 comprising aproximal end6 and adistal end8, that allows the device1 to be held in a pistol grip by the user, and atrigger lever16. The actuator handle12 is attached to apusher9 at the distal end ofhandle12. Thepusher9 comprises a ofshaft barrel assembly10 comprising a plurality of shaft segments capable of housing a drive shaft (not shown) that extend outwardly from a housing14 at thedistal end8 of theactuator handle12. Theshaft barrel assembly10 is comprised of at least two segments with symmetric coupling assemblies that are coupled to one another with a universal joint coupler (not shown). The coupled assembly is enclosed within a universaljoint sleeve18 such that the universal joint barrel is configured at an angle of about 30° from horizontal. Theshaft segment10 distal from theactuator handle12 is attached removably to asupport arm assembly22 that is comprised of a pair of “skeletalized” arms extending along mutually divergent axes so as to provide anopening23 to view thedevice working end19 during its operation. The workingend19 of the suturing device1 comprises acartridge holder assembly20 that is removably attached to thesupport arm assembly22, to which theneedle cartridge24 is disposably attached.
• FIGS. 2-13 provide detailed views of the various components of one embodiment of the suturing device1 and the manner in which the components are configured in the final assembled device to enable its operation via a “side-drive” mechanism in the manner described.
• FIG. 2 shows the workingend19 of the suturing device1 including the universaljoint coupling sleeve18, the universal joint segment distal to the actuator handle (not shown) a “pusher”9 comprising asupport arm assembly22 and acartridge holder assembly20 with an attacheddisposable needle cartridge24, and a universal joint assembly (hidden) encased in ajoint sleeve18.
• FIGS. 3A and 3B provide detailed segmental views of the suturing device working-end19 showing thedisposable needle cartridge24 in a disengaged mode and acurved suturing needle26 separated from theneedle cartridge24 to illustrate the relative configuration of these segments with respect to thecartridge holder assembly20, thepusher9 comprising thesupport arm assembly22 and the universal joint segments.FIG. 3A shows the coupled junction mode involving coupling of theshaft segments10 comprising a universal joint coupler (hidden), whileFIG. 3B shows the coupledshaft segments10 encased in a coupling joint sleeve or “sweep”18 that aligns thecartridge mount20 from the stem to the actuator handle at about 30°. Thesweep18 can be either pre-configured to provide a pre-determined fixed angle for the cartridge mount (relative to actuator handle), or can be configured to be adjustable to provide the user with the ability to vary the cartridge mount angle to a setting optimal for a particular procedure.
• FIGS.4A-C show expanded views of the hollow universal joint segment and the manner in which two identical segments are coupled. As shown inFIG. 4A, theshaft segment10 comprises a hollowcylindrical barrel28 with two open ends, and two pairs ofarcuate slots32 and34 at one end, wherein one pair of arcuate slots is narrower than the other. Additionally, the joint segment contains a plurality ofcircular openings36 located on the cylinder surface to accommodate a corresponding number of restraining pins in the universal joint sleeve (“sweep”)18 that are identical in diameter. Twoshaft segments10 having identicalarcuate slot configurations32 and34 may be coupled together using a universal joint coupler38 (FIG. 4B) comprising a plurality ofpins40 such that the coupler engages the pair ofnarrow slots32 of the conjoiningjoint segments32, thereby providing a junction connecting the twoshaft segments10 that is non-rigid (FIG. 4C). The angle between coupledsegments10 can, therefore, be varied. The coupledsegments10 provide a conduit for passage of a drive shaft (not shown) for activating needle movement.
• FIG. 5 shows a “tansparent” view of the universal joint sleeve or “sweep”18, which comprises of a hollow tubular segment with twoopen ends29,31 whose tubular axis bends over a predetermined angle. Thesleeve18 additionally comprises a plurality ofslots30 positioned along its side wall that are capable of engaging the correspondingslots36 on theshaft segments10 that are positioned appropriately by means of restraining bolts on pins38. Thesweep18 therefore, enables the angle of the coupledshaft segments10 to be “locked” in a preferred angle. Thesleeve18 can be configured to have either a fixed angle, or to have the capability to provide the user the ability to adjust the angle to a preferred setting. In one embodiment, thesweep18 provides an angle of about 30° from horizontal. The angle for the coupled universal joint10segments10 determined by the sweep in turn, determines the angle of thecartridge holder assembly20 which is attached to theshaft segment10 at thedistal end8 of the actuator handle12 (via the support arm assembly22). The cartridge holder angle relative to actuator handle12, in turn, determines the accessibility of the suturing device1 at the site of the suturing procedure which is critical, depending on whether it is open and planar, or non-planar and narrow.
• FIG. 6 shows a detailed view of thepusher9 that includes acartridge holder assembly20 that is attached to a support arm assembly comprising a pair of “skeletalized”support arms22 which in turn, is attached to the terminal end ofshaft segment10. The open configuration of the “skeletalized”support arms22 that are minimal in bulk is an essential feature of suturing device1 that provides a relativelywide opening23 that allows the user to directly view the aperture in the needle cartridge and cartridge (not shown)holder assembly20, the incision in the tissue and needle advancement through the incised tissue segments during operation of suturing device1. Although the embodiment shown inFIG. 6 has a plurality ofsupport arms22, other variants include a support arm assembly comprising a single support arm as illustrated inFIG. 11B. The improved viewing ability offered by the shape and configuration of thesupport arm assembly22 enables precise device placement over the incision, and uniform advancement of the suturing device after every stitch to provide a uniform and symmetric suture, thereby minimizing the risk of tearing tissue and bleeding due to a stitch being positioned too close to the edge of the incised tissue. Thecartridge holder assembly20 is composed of a sterilizable medical grade material which can either be a metallic material such as stainless steel to enable its reuse subsequent to sterilization following a prior use, or a sterilizable medical grade plastic material, in which case, it may discarded and disposed after a single use. Thecartridge holder assembly20 has a cylindrical configuration with adistal edge40 and aproximal edge42 with respect to the device actuator handle (not shown), with anaperture45 that corresponds in dimension and location to coincide with a substantially similar aperture located in the disposable needle cartridge. Thecartridge holder assembly20 additionally comprises a plurality ofslots44 located along on thedistal edge40 in that are located diametrically opposite to one another, and are capable of engaging the same plurality of retaining clips correspondingly located in the needle cartridge housing (not shown). Thecartridge holder assembly20 further comprises acylindrical slot46 located on thedistal edge40 that is capable of engaging a positioning pin of identical diameter correspondingly located on the needle cartridge housing (not shown). Theproximal edge42 of the cartridge holder assembly is attached to theshaft segment10 distal to the actuator handle12 via a support assembly comprising at least one “skeletalized”support arm22.
• FIGS. 7A and 7B show two different views of an embodiment of a disposablesuturing needle cartridge24 of the present invention, which is preferably offered in a sterilized sealed package. Thecartridge24 comprises acircular housing48 that may be formed of a suitable rigid medical grade sterilizable metal or plastic material. The housing may be releasably retained by thecartridge holder assembly20 at thedistal end19 of suturing device1 (working end) by known means, such as a plurality of clips50 (shown inFIG. 7A) located along on the edge of aninner lip52 in diametrically opposite positions that are capable of engaging the same plurality of slots correspondingly located in thecartridge holder assembly20. Thecartridge24 further comprises acylindrical positioning pin54 located on the edge of theinner lip52 that is capable of engaging a cylindrical slot of identical diameter correspondingly located on thecartridge holder assembly20. While the retaining clips50 when engaged enable the cartridge to be retained by thecartridge holder assembly20, thepositioning pin54 when engaged in the slot causes the aperture in thecartridge24 to be aligned with the corresponding aperture in thecartridge holder assembly20. Theneedle cartridge24 further comprises anaperture56 and a circular groove or “track”58 that is inscribed in the inside surface of thehousing48, which lies in a plane that is perpendicular to the longitudinal axis of both thehousing48 and that of the suturing device1. As shown inFIG. 7A, the cartridge-housing aperture56 interrupts thetrack58. An arcuatesurgical suturing needle26 composed of medical grade stainless steel or similar material is slidably positioned in thetrack58.
• FIGS. 8A and 8B show embodiments of thearcuate suturing needle26 of the present invention. In one embodiment (FIG. 8A), theneedle26 is formed as a circular split ring with agap59, a sharp, pointedend60, and ablunt end62. Theneedle26 further comprises an opening to accommodate the leading end of the suturing material. In one embodiment, the opening is the form of aneye64 though which the leading end of the suturing material may be passed through for attaching it to theneedle26. In the illustrated needle (FIG. 8A), theeye64 is located adjacent to theblunt end62. Theeye64 however, can be positioned anywhere along the arc or theneedle26 between its apex61 and theblunt end62. In a preferred embodiment (FIG. 8B), theneedle26 comprises an opening in the form of acylindrical bore66 aligned axially with respect to theneedle26, located at the blunt end62 (FIG. 8B). The leading end of the suturing material is inserted into the bore and restrained by mechanically crimping. To enable theneedle26 to penetrate tissue to the required depth, the needle preferably has an arcuate extent between about 280° and about 330°, and more preferably, greater than about 270°. Theneedle26 comprises twosymmetric notches68 along the radially inner edge (“inner notches”) that are positioned proximally to the sharp, pointedend60 and theblunt end62 of theneedle26. Thenotches68 are located directly opposite to each other, each having a 10 perpendicular (about 90°) segment and an angular segment that makes an angle of about 60° with the perpendicular segment. Theinner notches68 are engaged by the drive mechanism in thecartridge holder assembly20 and enable theneedle26 to undergo a rotatory movement upon actuation of the drive mechanism, thereby causing it to penetrate into and advance through tissue. A similartriangular notch70 is located on the radially outer edge (“outer notch”) of the needle proximally to theinner notch68 closer to the sharp, pointedend60. Theouter notch70 engages with an “anti-rotate” pin located in thecartridge holder assembly20, whereby rotation of theneedle26 in a direction opposite to the advancing direction or “needle backing-up” is prevented. The positive engagement of the needleouter notch70 during operation of the suturing device1, and thereby precludesneedle26 from straying out of sequence during the suturing process.
• The width of theaperture56 in thecartridge housing48 is comparable to and corresponds with the width of the gap in theneedle26 so that when theneedle26 is in the “home” position (as shown inFIG. 7A) it does not project materially into theaperture56. Such an alignment causes the needle to reside entirely within thecartridge holder20, thereby preventing inadvertent contact of the sharppointed end60 with the user's fingers during handling of thedisposable needle cartridge24 for its placement on thecartridge holder20 or its disposal after use, and while operating the suturing device1. Such protection of theneedle26 in the suturing device of the present invention prevents accidental “needle-pricks” from occurring, thereby substantially reducing the risk of infection caused by pathogenic bacteria or viruses that may contaminate the needle during or after its use prior to its disposal. Theneedle26 may be rotated in itscurved track58 about the longitudinal axis of the suturing device1 to advance thepointed needle tip60 so that the needle first spans the aperture and then return to its original or home position. Since the suturing material is attached to theneedle26, it follows the path of theneedle26. The terminal end of the suturing material may contain a knot or button to prevent it from pulling through the sutured tissue during placement of the first stitch. The suturing material or thread may be stored in an enclosed packaging either externally or internally with respect to theneedle cartridge housing48, and be pulled out of that packaging prior to placement of the first stitch in the suturing process. In a preferred embodiment, thecartridge housing48 comprise the suturingneedle26 attached to the terminal end suturing material or thread, and an appropriate length of suturing material are all packaged in a terminally sterilizable medical packaging material.
• FIG. 9 shows athread management roller72 of the present invention which acts to push the thread away from the track so the suture does not get pinched by the needle as the needle re-enters the track. Thethread management roller72 comprises a spring operatedstop pin74 that maintains a positive pressure against the suturing material or thread, thereby preventively retaining the suturing material in the thread retaining slot of the suturing needle, while keeping the thread out of the needle track to preclude the thread from jamming needle movement. Thestop pin74, therefore, prevents jamming of needle movement by an inadvertent entry of the suturing material into the needle slot within theneedle cartridge24 when the material is pulled forward by the advancing movement of theneedle26.
• FIG. 10 shows an expanded view of theanti-rotate pin75 that is capable of engaging the outer notch of theneedle26 to prevent rotation of theneedle26 and prevent “needle backing-up” and thereby precluding theneedle26 from straying out of sequence.
• FIG. 11B shows an expanded view of a pusherassembly comprising pusher76 and a pawl78 (FIG. 11A) located at its tip, which resides in a corresponding slot in thesupport arm22 of the pusher assembly, and is connected thesupport arm22 by apivot pin80. Theneedle26 is driven in a circular path by a rigid arm (“pusher”) that extends from a hub located in the center of the suturing device1. Thepawl78 at the tip of thepusher76 is capable of interfitting with the wedge shaped notches located along the radially inner edge of the needle. Thepusher76 is activated by the user upon operation of the actuator trigger in theactuator handle12, and is capable of sweeping back and forth in an arc spanning about 280°. The outer surface of thepusher76 is shaped to accommodate a C-shaped spring (not shown) that causes the wedge-shapedpawl78 to push up against theneedle26 and thereby remain in intimate contact. The advancing movement ofneedle26 during its operation causes thetriangular slots68 along the radially inner edge ofneedle26 align with the wedge-shapedpawl78 in thepusher76, thereby causing thepawl78 to engage theslots68 due to a positive pressure exerted on the pin by the C-shaped spring, and to “lock” into theslots68. The rotatory advancing movement of theneedle26 is therefore controlled to occur sequentially through about 280° each time it is actuated.
• FIG. 12 shows a cut-away segmental view of theneedle26 in the home position inside the cartridge (not shown) with respect to the stem cartridge holder assembly (not shown). The relative locations of thepawl78 that engages thenotches68 in the radially inner edge of theneedle26, thethread management roller72 and theanti-rotate pin75 that engages thenotch70 in the radially outer edge of theneedle26 are shown inFIG. 12.
• FIG. 13 shows a cut-away view of theneedle26 within the cartridge (not shown) in the “home” position, the alignment of the needle aperture with the corresponding aperture in theneedle cartridge holder20, the relative position of theneedle26 andcartridge holder20 and aperture location with respect to the coupledshaft segments10 that are coupled by universaljoint coupler38 and maintained at a fixed angle by the restraining coupling sleeve or “sweep” (not shown).
• FIGS. 14-20 show detailed component views of a preferred embodiment of the suturing device of the present invention and the manner in which the components are configured to enable its operation as described herein.
• FIG. 14 shows the working end of a preferred embodiment of the suturing device of the present invention, comprising a “pusher”9 having asupport arm assembly80 and acartridge holder assembly82 with the attacheddisposable needle cartridge84. The “pusher”9 is connected to the drive mechanism viashaft segment86 that is coupled via a universal joint coupling comprising a universal joint assembly encased in a sleeve (not shown) to a second shaft segment distal to theactuator handle12. Theshaft segment86 is attached to the universal joint assembly by pins that engageslots88 with corresponding slots in the coupling assembly.
• FIG. 15A shows segmental views of the pusher assembly comprising aneedle cartridge84 engaged withcartridge holder assembly82. Thecartridge84 attaches tocartridge holder assembly82 via a mountingclip90 located at the apex of the arc of thecartridge holder assembly82 that slidably “locks” into position with acomplementary slot92 located correspondingly on the apex ofcartridge84. Bothcartridge holder assembly82 andcartridge84 comprise anaperture96 that are of similar dimension, and aligned with one another in the “locked” position. Thecartridge84 further comprises a suturingmaterial management cleat98 which is capable of restrictibly maintainingsuturing material100 in a manner so as to preclude its entanglement as it travels intocartridge84 during operation of the suturing device.
• FIG. 15B shows a cut-away view of the pusher assembly exposing asuturing needle102 residing within cartridge84 (not shown) in the “home” position, wherein the alignment of the needle aperture corresponds with apertures of both needlecartridge holder assembly82, and thecartridge84. Theneedle102 is placed in the “home” position by engagingcartridge84 withcartridge holder assembly82 in a “locked position, whereupon it is restrained by clip104 in a manner causing it to be engaged with notches located along the radially rear edge of the needle (not shown) that is proximal tocartridge holder assembly82 by correspondingly located pins in a drive arm located in thecartridge holder assembly82 that is part of a “rear-drive” needle rotation drive operating mechanism.
• FIG. 16 shows a preferred embodiment of thecurved suturing needle102 of the invention. Theneedle102 is formed as a circular split ring with an aperture (or gap)106, as sharp, pointedend108 and theopposite end110. Acylindrical bore112 aligned axially with respect to the needle, located at the blunted110. The leading end of the suturing material is inserted into the bore and restrained by mechanically crimping. Alternatively, the opening for accommodating the suture material can be in the form of an “eye” wherein the leading end of the suturing material may be passed through for attaching it to theneedle102. To enable theneedle102 to penetrate tissue to the required depth, theneedle102 preferably has an arcuate extent between about 280° and about 330°, and more preferably, greater than about 270°.Needle26 comprises two symmetric notches (“rear notches”)114 along the radially rear edge, i.e. the edge proximal to thecartridge holder82, that are positioned proximally to the sharppointed end108 and the oppositeblunt end110 of theneedle102, respectively. Therear notches114 are located directly opposite to one another, each having a perpendicular (about 90°) segment and an angular segment that makes an angle of about 60° with the perpendicular segment. Therear notches114 are engaged by the drive mechanism in the cartridge holder assembly and enable the needle to undergo a rotational movement upon actuation of the drive mechanism, thereby causing it to penetrate and advance through tissue. A similartriangular notch116 is located on the radially outer edge (“outer notch”) of the needle proximally to therear notch114 that is closer to the sharp, pointedend108. Theouter notch116 engages with an “anti-rotate” pin located in the cartridge holder assembly, whereby rotation of the needle in a direction opposite to the advancing direction or “needle backing-up” is prevented. The positive engagement of the needleouter notch116 during operation, therefore, precludes the needle from straying out of sequence during the suturing process.
• FIGS. 17A and 17B show the outer and inner views, respectively, of thecartridge84.
• The outer surface of the cartridge84 (FIG. 17A) comprises a suturingmaterial management cleat98 which is capable of restrictibly maintaining the suturing material in a manner to preclude its entanglement. Thecartridge84 further comprises aslot92 located at the apex of an actuate edge that slidably engages a complementarily located pin on the cartridge holder assembly to “lock” it in position. The inner surface of thecartridge84 comprises atrack118 that permits the suturing needle (not shown) housed within to travel in a rotational motion from its “home position” so as to spanaperture106 during operation. Aslot120 located radially on the inner surface ofcartridge84 engages with a complementarily located pin on the cartridge holder assembly such that when the pin is engaged slidably inslot120, the needle is constrained to remain in and move alongtrack118.
• FIG. 18 shows a top sectional view of a preferred embodiment of a “pusher”9 comprising acartridge holder assembly82 andsupport arms22. Thecartridge holder assembly82 comprises a plurality of mountingclips122 that are capable of receiving thecartridge84, and a mountingclip90 at the apex of the radial edge and slidably engaging a complementarily located slot in the cartridge that engagescartridge holder assembly82, thereby causing the drive mechanism in theassembly82 to engage the suturing needle housed within the cartridge. Thecartridge holder assembly82 further comprises agate assembly124 that preventsneedle102 from leaving its track and falling out into the back of thecartridge holder assembly82. Thegate assembly124 is maintained in a closed “home” position by a torque force exerted by aspring126 to which it is coupled via apin128, thereby restricts lateral movement ofneedle102. Thegate assembly124 opens during each actuation of the suturing device to permit a circular movement of the drive mechanism that engagesneedle102, and closes to the home position immediately after passage of the drive mechanism to preclude lateral movement and dislocation ofneedle102 withincartridge holder assembly82.
• FIGS. 19A, 19B and19C show serial views of the “rear-drive” needle operating drive mechanism operating within thecartridge holder82 of the pusher assembly (not shown). The “rear-drive” mechanism comprises adriver arm130 connected to adrive shaft132 that is capable of circular motion so as to “sweep” along the circular inner edge of thecartridge holder82 comprising thegate assembly124. Actuation of the device causes thedrive shaft132 to rotate in a clockwise direction, thereby causingdriver arm130 to move circularly from its “home” rest position and move up to and thepast gate assembly124, causing it to open in the process (FIGS. 19A and 19B). Thedriver arm130 continues to move circularly until it comes to rest once again in the “home” position (FIG. 19C). Thegate assembly124 returns to its closed home position after passage of thedriver arm130, thereby allowingdriver arm130 to “drive”needle102 in a circular motion, while preventing theneedle102 from becoming dislocated fromtrack118. Thus, each time suturing device1 is actuated,driver arm130 moves past thegate assembly124, opening thegate assembly124 in the process. Since thegate assembly124 moves back into its closed “home” position after passage of thedriver arm130, it precludes lateral movement of theneedle102, thereby preventingneedle102 from jamming due to misalignment during operation.
• FIGS. 20A, 20B and20C show the dimensional, sectional and transparent sectional views, respectively, of aratchet assembly134 of the present invention that is part of the drive mechanism for the suturing device1.FIG. 20A shows theratchet assembly134 comprises aratchet ring136 with a predominantly arcuateouter surface segment137 having a plurality ofteeth138, and an arcuateflat segment140 that having a planar surface. Theratchet ring136 includes a central circular bore (not shown) that fits slidably over and attaches immovably to apinion gear142 comprising ashaft144. Theratchet ring136 further comprises a plurality of wedgedsurfaces139aand139bthat are proximal to theflat segment140. Theratchet assembly134 is mounted on a base146 comprising ahousing148 that accommodates a pawl (hidden) that is activated by a coil spring (not shown) and ashuttle150, that is attached to asupport bracket152 by a plurality ofscrews153.FIG. 20B shows a detailed sectional view of theratchet ring136 comprising acircular bore154 that is capable of slidably receiving and attaching to theshaft144 of the pinion gear142 (not shown). Theratchet ring136 is mounted on the base146 so that theteeth138 of theratchet ring136 are interactively meshed with thepawl156. Thepawl156 is activated by a coil spring (not shown) that exerts a positive pressure on thepawl156 causing it to remain in intimate contact with theteeth138 of theratchet ring136. Theshuttle150 is attached to the base so that it allows theratchet ring136 to rotate in a unidirectional (such as, for example, clockwise) until the circular movement is arrested by contact between theshuttle150 and afirst wedge139ain theratchet ring136. Movement of theshuttle150 after contacting thefirst wedge139apermits theratchet ring136 to rotate in a direction opposite to the initial direction of rotation (such as, for example, counter-clockwise) until the movement is stopped by contact ofshuttle150 with thesecond wedge139b.FIG. 20C shows a transparent sectional view of theratchet ring136 where theteeth138 of theratchet ring136 are enmeshed with thepawl156, which is maintained in intimate contact with theteeth138 by a positive pressure exerted by the action of acoil spring158.
• Theratchet assembly134 of the present invention may be suitably located within thehandle12 of the suturing device1. In a preferred embodiment, theratchet assembly134 is located at thedistal end8 of theactuator handle12, whereby theshaft144 of theratchet assembly134 is a part of ashaft segment10 that is terminally attached to a triggering mechanism of the suturing device1. Activation of the suturing device1 by actuating the triggering mechanism (not shown) via thetrigger16 in the actuator handle12 causes theshaft144 and the attachedratchet ring136 and thepinion gear142 in theratchet mechanism134 to rotate unidirectionally, thepinion gear142 to drive theshaft segment10 coupled to thedriver arm130 of the rear-drive mechanism in thepusher9, which in turn, causes the engagedneedle102 to rotate in the same direction to effectuate penetration of incised tissue by theneedle102 pulling the suturing thread material with it. The rotation of theshaft144 is arrested after travelling about 280° upon contact by afirst wedge139awith theshuttle150, which in turn, terminates the first actuation step. Theshuttle150 then permits theshaft144 with the attachedratchet ring136 and thepinion gear142 to rotate through an equal distance in the opposite direction until the movement is stopped once again by the contact by theshuttle150 with thesecond wedge139b. An advantage offered by theratchet mechanism134 of the present invention is that the actuation step of the suturing device1 is pre-determined, that is, theratchet assembly134 prevents the user from performing an incomplete actuating event that could result in an improper or incomplete suture by causing theneedle102 to snag in the tissue. Furthermore, theratchet assembly134 is capable of operation by thetrigger16 in a manner independent of its orientation with respect to thetrigger16 and actuator handle12, such as for example, when it is oriented in an upside down or sideways configuration.
• The actuating means of the suturing device1 of the present invention may comprise of a triggering mechanism that is known in the art, such as for example, the triggering mechanisms disclosed in U.S. Pat. Nos. 6,053,908 and 5,344,061, both of which are hereby incorporated by reference. Alternatively, the actuating means can be either a manually operable button or switch, or a mechanically operable by an automated electrical or a fuel driven device, such as for example, an electrical, electromagnetic or pneumatic motor powered by electrical, electromagnetic, compressed air, compressed gas, hydraulic, vacuum or hydrocarbon fuels.
• To commence suturing, any embodiment of the suturing device1 of the present invention is placed at the site of the wound or tissue incision such that it spans the wound or the two tissue segments created by the incision, following which it is actuated by operation of theactuator trigger16 on theactuator handle12. The detailed operation of the suturing device1 of the present invention is described with reference to the preferred embodiment, and is equally applicable to all other embodiments of the invention described and contemplated herein. Thepawl156 in the pusher mechanism of the suturing device1 engages thenotch114 located radially rear edge proximal to the blunt end or “tail” of thesuturing needle102 and pushes the needle in a circular path in an arc spanning about 280°. The sharp, pointedend108 of theneedle102 crosses theaperture96 defined by thecartridge84 and thecartridge holder82, and penetrates the first tissue segment located within theaperture96, traverses the tissue segment to penetrate the second tissue segment, and re-enters the device on the opposite side of theaperture96. Thepusher9 then returns to its original location, whereupon thepawl156 engages the notch located radiallyrear edge114 proximal to the sharp, pointed end of theneedle102. Theneedle102 with the attached suturing material or thread is consequently pulled in a circular path through an arc of about 280°. Theblunt end110 of theneedle102 and the suturing material therefore, pass through the tissue segments and across the wound or incision so as to span the wound or incision. Theneedle102 comes to rest at its original “home” position within the track incartridge holder82, having advanced through a complete circular arc of about 360°. Theneedle102 including the sharp, pointedend102 remains entirely contained within thecartridge84. The suturing material or thread may then be cut and secured by an appropriate method, such as for example, by tying, or additional stitches may be placed along the entire wound or incision by repeating the aforementioned process. Every stitch, whether a single, interrupted stitch, or one of a series of continuous, running stitches may be placed in like manner. The suturing device1 of the present invention, therefore, may be used to insert either a single stitch, or to insert a suture comprising a plurality of continuous stitches as a replacement method for a more tedious and time-consuming manual suturing process.
• While a suturing device1 having theseparable suture cartridge84 containing thesuturing needle102, apusher9 comprising acartridge holder82 with thesupport arms80, a drive shaft assembly comprising thedriver arm130, and anactuator handle12 comprising theactuating trigger16 and drive mechanism has been described, the entire suturing device1 can be designed as a single unit which may be either reusable or disposed in its entirety after a single use.
• It will thus be seen that the examples set forth above among those made apparent from the preceding description are efficiently attained in the suturing device of the present invention. Also, since certain changes may be made in the above description without departing from the scope of the invention, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative, and not in a limiting sense.

Claims (20)

1. A cartridge for a suturing device comprising:

a curved housing having a first end and a second end separated by an aperture in a wall of the curved housing; and

a track in the wall of the curved housing, the track supporting a suturing needle.

2. The cartridge ofclaim 1 wherein the curved housing traverses an arc greater than about 180 degrees.

3. The cartridge ofclaim 1 wherein the track is semi-cylindrical and located on an inner surface of the cartridge.

4. The cartridge ofclaim 1 wherein the cartridge shields the suturing needle at an end of a revolution of the suturing needle.

5. The cartridge ofclaim 1 wherein the cartridge is disposable.

6. The cartridge ofclaim 1 further comprising at least one mounting clip for releasably engaging the cartridge with a cartridge holder of the suturing device.

7. The cartridge ofclaim 1 further comprising a suturing material dispenser containing a suturing material.

8. The cartridge ofclaim 1 wherein the suturing needle follows the track in the wall of the curved housing through successive revolutions of the suturing needle.

9. The cartridge ofclaim 1 wherein the track contains at least a portion of the suturing needle during an entire revolution of the suturing needle.

10. The cartridge ofclaim 1 wherein a pointed end of the suturing needle exits a first end of the track in the wall of the curved housing and enters a second end of the track in the wall of the curved housing.

11. The cartridge ofclaim 1 wherein a length of the suturing needle is less than a length of the track of the curved housing.

12. A cartridge for housing a suturing needle comprising:

a housing having a curved shape, an inner wall and an outer wall;

a groove in the inner wall of the housing whereby the suturing needle follows a curved path along the groove during a revolution of the suturing needle; and

an aperture in the housing that intercepts the groove,

wherein the housing shields a pointed end of the suturing needle during at least a portion of the revolution of the suturing needle.

13. The cartridge ofclaim 12 wherein the cartridge is disposable.

14. The cartridge ofclaim 12 wherein the suturing needle follows the groove in the wall of the housing through successive revolutions of the suturing needle.

15. The cartridge ofclaim 12 wherein the groove contains at least a portion of the suturing needle during an entire revolution of the suturing needle.

16. The cartridge ofclaim 12 wherein a pointed end of the suturing needle exits a first end of the groove in the inner wall of the housing and enters a second end of the groove in the inner wall of the curved housing.

17. The cartridge ofclaim 12 wherein a length of the suturing needle is less than a length of the groove of the housing.

18. A cartridge housing a suturing needle for use in suturing, the suturing needle comprising:

a pointed end at a first end of the suturing needle that is protected at an end of a rotation cycle;

a blunt end at a second end of the suturing needle;

a gap between the pointed end and the blunt end; and

an eye adjacent to the blunt end for engaging a suturing material,

wherein the suturing needle is in an arcuate shape between the pointed end and the blunt end.

19. The cartridge housing the suturing needle ofclaim 18 wherein the suturing needle further comprises a first inner notch and a second inner notch located opposite the first inner notch.

20. The cartridge housing the suturing needle ofclaim 18 wherein the suturing needle rotates in a track of a cartridge.

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