FIELD OF THE INVENTION

Embodiments of the present invention relate to medical devices. In particular, embodiments of the present invention include a medical device having a tensionable coupling.

BACKGROUND OF THE INVENTION

Minimally invasive surgical tools, such as endoscopic and laparoscopic devices, can provide access to surgical sites while limiting patient trauma. Although the growing capabilities of such therapeutic devices allow physicians to perform an increasing variety of surgeries, improvements are needed to further develop these devices. For example, the performance of some devices can vary if the device has been subjected to temperature or pressure variations.

Some minimally invasive systems use cables, wires, ribbons, rods, or other elongate members to control various device functions, including articulation of a steering section or actuation of an end-effector. These control members may be affected by manufacturing processes, shipping, or storage conditions. For example, contraction or expansion of a control member or a supporting structure can adversely affect device performance. The present invention aims to overcome these and other limitations of conventional devices.

SUMMARY OF THE INVENTION

The medical devices described herein can be provided in an untensioned state and later tensioned for use. Such a tensionable device could be stored or shipped in an untensioned state, and tensioned immediately prior to use by a surgeon. The device may also be configured to automatically lock in the tensioned state or adapted for use with different types of end-effectors. Once locked, an end-effector could be rotated relative to the device to customize the device's orientation.

One aspect of the invention is directed to a medical device having an elongate shaft having a distal end and a controller coupled to the shaft. A control member can extend through at least part of the elongate shaft and at least part of the controller, wherein the control member in a tensioned configuration can be moveable by the controller to control the distal end of the shaft and the control member can be slack in an untensioned configuration. A tensioning mechanism can be configured to move relative to at least one of the elongate shaft and the controller to tension the control member and automatically lock the control member in the tensioned configuration.

According to another aspect, the invention can include a method of pre-tensioning a control member extending within at least part of an elongate shaft and at least part of a controller of a medical device. The method can include mounting a pivot assembly in a fixed position relative to a tensioning fixture, wherein the pivot assembly can be moveably coupled to the controller. The method can also include passing the control member through the pivot assembly, applying a preset tension to the control member, attaching the control member to the pivot assembly, and un-mounting the pivot assembly from the tensioning fixture.

According to another aspect, the invention can include a controller for use with a medical device. The controller can include a base coupled to a catheter configured for use with an endoscopic device and a handle moveably coupled to the base and configured to move a control member to control a distal region of the catheter. The controller can further include a pivot assembly coupling the handle to the base and including a pulley. The pulley can include an attachment mechanism configured to attach the control member to the pulley and permit a proximal region of the control member to extend proximally beyond the pulley and a surface configured to receive a stabilizing member, wherein the stabilizing member can be positionable against the surface to limit movement of the pulley relative to the base and permit application of a select tension to the control member prior to attaching the control member to the pulley.

According to another aspect, the invention can include a method of tensioning and untensioning a medical device. The method can include moving a controller axially relative to a catheter to transition a control member from an untensioned state to a tensioned state and to automatically lock axial movement of the controller and the catheter in the tensioned state, wherein movement of the control member in the tensioned state by the controller can control a distal end of the catheter. The method can also include selectively unlocking axial movement between the controller and the catheter to transition the control member from the tensioned state to the untensioned state.

Additional objects and advantages of the invention will be set forth in part in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention will be realized and attained by means of the elements and combinations particularly pointed out in the appended claims.

It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention, as claimed.

