Medical device actuators

Abstract

The present invention provides a flexible actuator, and methods for manufacturing and using a flexible actuator, for transmitting high loads from a user to an end effector. In one exemplary embodiment, the flexible actuator can extend from a handle of a medical device to an end effector located on a distal end of the device. The actuator can include a head formed on a terminal end thereof with at least one planar surface that is approximately coplanar with an outer surface of the flexible actuator. In use, the actuator can be coupled to a medical device having an end effector located on a distal end thereof. Tension applied to the actuator can be effective to actuate the end effector.

1 . A medical device, comprising:
 an elongate member having first and second jaws formed on a distal end thereof that are adapted to manipulate tissue; and   a flexible wire extending through the elongate member and having a distal portion extending from an inner surface of one of the jaws and through a bore in the jaw, the flexible wire having a head formed on a terminal end thereof that terminates adjacent to an outer surface of the jaw, the head including a planar surface that is coplanar with an outer surface of the flexible wire.   
   
   
       2 . The device of  claim 1 , wherein the distal portion of the flexible wire extends perpendicularly outward from a plane extending through a central axis of the elongate member. 
   
   
       3 . The device of  claim 1 , wherein the head is substantially D-shaped. 
   
   
       4 . The device of  claim 2 , wherein the D-shaped head includes proximal and distal facing surfaces and a sidewall extending between the proximal and distal facing surfaces, the sidewall including an arc shaped region and a planar region such that a perimeter of the sidewall is D-shaped. 
   
   
       5 . The device of  claim 4 , wherein the planar region of the sidewall is coplanar with an outer surface of the flexible wire. 
   
   
       6 . The device of  claim 4 , wherein the distal facing surface is substantially planar. 
   
   
       7 . The device of  claim 4 , wherein the terminal end of the flexible wire abuts the proximal facing surface of the D-shaped head. 
   
   
       8 . The device of  claim 7 , wherein the terminal end of the flexible wire flares outward toward the proximal facing surface of the D-shaped head. 
   
   
       9 . The device of  claim 1 , wherein the bore in the jaw is non-chamfered such that the head rests against an outer surface of the jaw. 
   
   
       10 . The device of  claim 1 , wherein the flexible wire has a bend formed therein between a proximal portion of the flexible wire and the distal portion, the bend being positioned adjacent to the inner surface of the jaw through which the flexible wire extends. 
   
   
       11 . The device of  claim 10 , wherein the distal portion of the wire located distal of the bend has a length in the range of about 0.01 inches to 0.02 inches. 
   
   
       12 . The device of  claim 10 , wherein the bend has an angle of about 90°. 
   
   
       13 . The device of  claim 1 , wherein the flexible wire has a termination strength of at least about 12 lbs. 
   
   
       14 . The device of  claim 1 , wherein the flexible wire has a termination strength of at least about 17 lbs. 
   
   
       15 . A medical device, comprising:
 an elongate member having an end effector located on a distal end thereof; and   a flexible actuator extending through the elongate member and having formed at its distal end a head having at least one planar surface that is coplanar with an outer surface of the elongate member, and having a maximum width greater than a maximum of the flexible actuator, a distal portion of the flexible actuator extending perpendicularly outward from a plane extending through a central axis of the elongate member, and extending through a bore in the end effector such that the head terminates adjacent to an outer surface of the end effector.   
   
   
       16 . The medical device of  claim 15 , wherein the head is D-shaped and includes an arc shaped sidewall and a planar sidewall, the planar sidewall being coplanar with an outer surface of the flexible actuator. 
   
   
       17 . The medical device of  claim 15 , wherein the distal portion is located just distal of a substantially 90° bend formed in the flexible actuator. 
   
   
       18 . The medical device of  claim 17 , wherein the distal portion has a length in the range of about 0.01 inches to 0.02 inches. 
   
   
       19 . The medical device of  claim 15 , wherein the head and the flexible actuator are integrally formed. 
   
   
       20 . A method for processing the medical device of  claim 15  for surgery, comprising:
 a) obtaining the medical device of  claim 1 ;   b) sterilizing the medical device; and   c) storing the medical device in a sterile container.   
   
   
       21 . A method for manufacturing an actuator for a surgical device, comprising:
 forming a D-shaped head on a distal end of a wire;   grasping the D-shaped head with a forming shoe of a forming tool such that a planar surface of the D-shaped head and a distal portion of the wire rest against a planar surface of the forming shoe; and   actuating the forming tool to form a bend just proximal to the D-shaped head of the wire.   
   
   
       22 . The method of  claim 21 , wherein the D-shaped head and the wire are integrally formed. 
   
   
       23 . The method of  claim 21 , wherein the bend has an angle of about 90°. 
   
   
       24 . The method of  claim 21 , wherein a portion of the wire located distal of the bend has a length in the range of about 0.01 inches to 0.02 inches. 
   
   
       25 . The method of  claim 21 , wherein the planar surface on the D-shaped head is formed around a D-shaped perimeter of a sidewall of the D-shaped head, the sidewall extending between proximal and distal facing surfaces of the D-shaped head. 
   
   
       26 . The method of  claim 21 , further comprising attaching the wire to a surgical device having an elongate member and a pair of jaws such that the wire extends through the elongate member and a portion of the wire located distal to the bend extends from an inner surface of one of the jaws through a bore formed in the jaw, the D-shaped head terminating adjacent to an outer surface of the jaw. 
   
   
       27 . The method of  claim 26 , further including the step of sterilizing said device after at least one use.