CN114945333A - Electrosurgical instrument with flexible wiring assembly - Google Patents

Abstract

An electrosurgical instrument includes a housing, a shaft extending from the housing, an end effector extending from the shaft, an articulation joint rotatably connecting the end effector to the shaft, and a wiring circuit. The housing includes a printed circuit control board. The wiring circuit extends from the printed circuit control board through the shaft and into the end effector. The wiring circuit is configured to monitor the function of the end effector and communicate the monitored function to the printed circuit control board. The wiring circuit includes a proximal rigid portion fixed to the shaft, a distal rigid portion fixed to the end effector, and an intermediate portion extending from the proximal rigid portion to the distal rigid portion. The intermediate portion includes a resilient portion and a stretchable portion.

Description

Electrosurgical instrument with flexible wiring assembly

Cross Reference to Related Applications

The present non-provisional application claims the benefit of U.S. provisional patent application serial No. 62/955,299 entitled "DEVICES AND SYSTEMS FOR ELECTROSURGERY" filed on 30.12.2019 as 35 u.s.c. § 119(e), the disclosure of which is incorporated herein by reference in its entirety.

Background

The present invention relates to surgical instruments designed for treating tissue, including but not limited to surgical instruments configured to cut and fasten tissue. The surgical instrument may include an electrosurgical instrument powered by a generator to effect tissue dissection, cutting and/or coagulation during a surgical procedure. The surgical instrument can include an instrument configured to cut and staple tissue using surgical staples and/or fasteners. The surgical instrument may be configured for open surgical procedures, but may also be applied to other types of surgical procedures, such as laparoscopic, endoscopic, and robotically-assisted procedures, and may include an end effector that is articulatable relative to a shaft portion of the instrument to facilitate precise positioning within a patient.

Disclosure of Invention

In various embodiments, an electrosurgical instrument is disclosed that includes a housing, a shaft extending from the housing, an end effector extending from the shaft, an articulation joint rotatably connecting the end effector to the shaft, and a wiring circuit. The housing includes a printed circuit control board. The wiring circuit extends from the printed circuit control board through the shaft and into the end effector. The wiring circuit is configured to monitor the function of the end effector and communicate the monitored function to the printed circuit control board. The wiring circuit includes a proximal rigid portion fixed to the shaft, a distal rigid portion fixed to the end effector, and an intermediate portion extending from the proximal rigid portion to the distal rigid portion. The intermediate portion includes a resilient portion and a stretchable portion.

In various embodiments, an electrosurgical instrument is disclosed that includes a housing, a shaft extending from the housing, an end effector extending from the shaft, an articulation joint rotatably connecting the end effector to the shaft, and a wiring circuit. The housing includes a printed circuit control board. The wiring circuit extends from the printed circuit control board through the shaft and into the end effector. The wiring circuit is configured to monitor the function of the end effector and communicate the monitored function to the printed circuit control board. The wiring circuit includes a rigid portion, a resilient portion capable of transitioning between a relaxed configuration and a non-relaxed configuration, and a wire extending through the resilient portion. The wire includes a stretchable portion. The wire is configured to be capable of being elongated when the resilient portion transitions from the relaxed configuration to the non-relaxed configuration.

In various embodiments, an electrosurgical instrument is disclosed that includes a housing, a shaft extending from the housing, an end effector extending from the shaft, a translating member configured to translate relative to the shaft to perform an end effector function, and a wire harness. The housing includes a printed circuit control board. A wiring harness extends from the printed circuit control board into the shaft. The wire harness includes a rigid body portion secured to the shaft, a resilient portion extending from the rigid body portion, and a wire extending through the rigid body portion and the resilient portion. One end of the resilient portion is attached to the translating member. The end of the resilient portion attached to the translating member includes a sensor configured to measure a property of the translating member.

Drawings

The novel features of the various aspects are set forth with particularity in the appended claims. However, the described aspects, both as to organization and method of operation, may best be understood by reference to the following description, taken in conjunction with the accompanying drawings in which:

fig. 1 illustrates an example of a generator for use with a surgical system according to at least one aspect of the present disclosure;

FIG. 2 illustrates one form of a surgical system including a generator and an electrosurgical instrument usable therewith, in accordance with at least one aspect of the present disclosure;

FIG. 3 illustrates a schematic view of a surgical instrument or tool in accordance with at least one aspect of the present disclosure;

FIG. 4 is a side elevational view of an end effector for use with an electrosurgical instrument, according to at least one aspect of the present disclosure;

FIG. 5 is a side elevational view of the end effector of FIG. 4 in a closed configuration;

FIG. 6 is a plan view of one of the jaws of the end effector of FIG. 4;

FIG. 7 is a side elevational view of the other of the jaws of the end effector of FIG. 4;

FIG. 8 is a side elevational view of an end effector for use with an electrosurgical instrument, according to at least one aspect of the present disclosure;

FIG. 9 is an end view of the end effector of FIG. 8;

FIG. 10 is an exploded perspective view of one of the jaws of the end effector of FIG. 8;

FIG. 11 is a cross-sectional end view of an end effector for use with an electrosurgical instrument according to at least one aspect of the present disclosure;

FIG. 12 is a cross-sectional end view of an end effector for use with an electrosurgical instrument according to at least one aspect of the present disclosure;

FIG. 13 is a cross-sectional end view of an end effector for use with an electrosurgical instrument according to at least one aspect of the present disclosure;

FIG. 14 is a cross-sectional end view of an end effector for use with an electrosurgical instrument according to at least one aspect of the present disclosure;

FIG. 15 is a cross-sectional end view of an end effector for use with an electrosurgical instrument according to at least one aspect of the present disclosure;

FIG. 16 is a cross-sectional end view of an end effector for use with an electrosurgical instrument according to at least one aspect of the present disclosure;

FIG. 17 is a cross-sectional end view of an end effector for use with an electrosurgical instrument according to at least one aspect of the present disclosure;

FIG. 18 is a cross-sectional end view of an end effector for use with an electrosurgical instrument according to at least one aspect of the present disclosure;

FIG. 19 is a graph illustrating a power scheme for coagulating and cutting a tissue treatment region during a treatment cycle applied by an end effector, according to at least one aspect of the present disclosure;

FIG. 20 is a perspective view of a surgical instrument including a flexible wiring assembly according to at least one aspect of the present disclosure;

FIG. 21 is a partial side elevational view of the flexible wiring assembly of FIG. 20 in a relaxed configuration;

FIG. 22 is a partial side elevational view of the flexible wiring assembly of FIG. 20 in a stretched configuration;

FIG. 23 is a perspective view of a wire harness and inductive sensor for use with a surgical instrument according to at least one aspect of the present disclosure;

FIG. 24 is a perspective view of a flexible wiring harness and inductive sensor for use with a surgical instrument according to at least one aspect of the present disclosure;

FIG. 25 is an enlarged view of a portion of the flexible wiring harness of FIG. 24;

fig. 26 is a perspective view of a surgical instrument including a manual switching member according to at least one aspect of the present disclosure;

FIG. 27 is an end cross-sectional view of the manual switching member of FIG. 26, showing the manual switching member in a rotated position;

fig. 28 is an end cross-sectional view of the manual switching member of fig. 27 in a centered position;

FIG. 29 is a schematic view of the surgical instrument of FIG. 26;

FIG. 30 is an exploded perspective view of the surgical instrument of FIG. 26 showing a manual switch member and an elongate shaft;

FIG. 31 is a plan view of the elongate shaft of FIG. 30 showing the position of the elongate shaft when the manual rocker member is in the centered position;

FIG. 32 is a plan view of the elongate shaft of FIG. 30 showing the position of the elongate shaft when the manual switch member is rotated counterclockwise;

FIG. 33 is a plan view of the elongate shaft of FIG. 30 showing the position of the elongate shaft when the manual switch member is rotated clockwise;

FIG. 34 is a schematic view of a surgical system according to at least one aspect of the present disclosure;

FIG. 35 is a graph of battery recharge rate, battery charge percentage, power draw, and motor speed over time for the surgical system of FIG. 34;

FIG. 36 is a side view of a surgical system including a surgical instrument, a monopolar power generator, and a bipolar power generator according to at least one aspect of the present disclosure; and is

Fig. 37 is a schematic representation of battery charge percentages and motor torques over time for a plurality of surgical instrument systems according to at least one aspect of the present disclosure.

Detailed Description

The applicant of the present application owns the following U.S. patent applications filed on even date herewith and each incorporated herein by reference in its entirety:

attorney docket number END9234USNP1/190717-1M, entitled "METHOD FOR AN ELECTRROSURGICAL PROCEDURE";

attorney docket number END9234USNP2/190717-2 entitled "articulable minor instroment";

attorney docket number END9234USNP3/190717-3 entitled "SURGICAL INSTRUMENT WITH JAW ALIGNMENT FEATURES";

attorney docket number END9234USNP4/190717-4 entitled "SURGICAL INSTRUMENT WITH ROTATABLE AND ARTICULATABLE SURGICAL END EFFECTOR";

attorney docket number END9234USNP5/190717-5, entitled "ELECTROSURURGICAL INSTRUMENT WITH ASYNCHRONOUS ENERGIZING ELECTRODES";

attorney docket number END9234USNP6/190717-6 entitled "ELECTROSTROSURGICAL INSTRUMENT WITH ELECTROSTRODES BIASING SUPPORT";

attorney docket number END9234USNP8/190717-8 entitled "ELECTROSURURGICAL INSTRUMENT WITH VARIABLE CONTROL MECHANISMS";

attorney docket number END9234USNP9/190717-9, entitled "ELECTROSTROSURGICAL SYSTEMS WITH INTEGRATED AND EXTERNAL POWER SOURCES";

attorney docket number END9234USNP10/190717-10 entitled "ELECTROSURURGICAL INSTRUMENTS WITH ELECTRODES HAVING ENERGY FOCUSING FEATURES";

attorney docket number END9234USNP11/190717-11 entitled "ELECTROSURURGICAL INSTRUMENTS WITH ELECTRODES HAVARIABLE ENERGY DENSITIES";

attorney docket number END9234USNP12/190717-12 entitled "ELECTROSURURGICAL INSTRUMENT WITH MONOPOLAR AND BIPOLAR ENERGY CAPABILITIES";

attorney docket number END9234USNP13/190717-13 entitled "ELECTROSTROSURGICAL END EFFECTORS WITH THERMALLY INSULATED AND THERMALLY CONDUCTIVE PORTIONS";

attorney docket number END9234USNP14/190717-14 entitled "ELECTROSURURGICAL INSTRUMENT WITH ELECTRODES OPERABLE IN BIPOLAR AND MONOPOLAR MODES";

attorney docket number END9234USNP15/190717-15, entitled "ELECTROSURURGICAL INSTRUMENTS FOR DELIVERING BLENDED ENERGY MODALIES TO TISSUE";

agent case number END9234USNP16/190717-16, entitled "CONTROL PROGRAM ADAPTATION BASED ON DEVICE STATUS AND USER INPUT";

attorney docket number END9234USNP17/190717-17 entitled "CONTROL PROGRAM FOR MODULAR COMMUNICATION ENERGY DEVICE"; and

attorney docket number END9234USNP18/190717-18, entitled "SURGICAL SYSTEM COMMUNICATION PATHWAYS".

The applicant of the present application owns the following U.S. provisional patent applications filed on 30.12.2019, the disclosures of each of which are incorporated herein by reference in their entirety:

U.S. provisional patent application Ser. No. 62/955,294 entitled "USER INTERFACE FOR SURGICAL INSTRUMENTATION WITH COMMUNICATION ENERGY MODULATION END-EFFECTOR";

U.S. provisional patent application Ser. No. 62/955,292 entitled "COMMUNICATION ENERGY MODALITY END-EFFECTOR"; and

U.S. provisional patent application serial No. 62/955,306, entitled "SURGICAL INSTRUMENT SYSTEMS".

The applicant of the present application owns the following U.S. patent applications, the disclosures of each of which are incorporated herein by reference in their entirety:

U.S. patent application Ser. No. 16/209,395, entitled "METHOD OF HUB COMMUNICATION", now U.S. patent application publication No. 2019/0201136;

U.S. patent application Ser. No. 16/209,403, entitled "METHOD OF CLOUD BASED DATA ANALYTICS FOR USE WITH THE HUB", now U.S. patent application publication No. 2019/0206569;

U.S. patent application Ser. No. 16/209,407 entitled "METHOD OF ROBOTIC HUB COMMUNICATION, DETECTION, AND CONTROL", now U.S. patent application publication No. 2019/0201137;

U.S. patent application Ser. No. 16/209,416 entitled "METHOD OF HUB COMMUNICATION, PROCESSING, DISPLAY, AND CLOUD ANALYTICS", now U.S. patent application publication No. 2019/0206562;

U.S. patent application Ser. No. 16/209,423, entitled "METHOD OF COMPRESSING TISSUE WITHIN A STAPLING DEVICE AND SIMULTANEOUSLY DISPLAYING THE LOCATION OF THE TISSUE WITHIN THE JAWS", now U.S. patent application publication No. 2019/0200981;

U.S. patent application Ser. No. 16/209,427 entitled "METHOD OF USING INFORMATION FLUX CIBLE CIRCULATIES WITH MULTIPLE SENSOR TO OPTIMIZATION PERFOMANCE OF RADIO FREQUENCY DEVICES", now U.S. patent application publication No. 2019/0208641;

U.S. patent application Ser. No. 16/209,433, entitled "METHOD OF SENSING PARTITITE FROM SMOKE EVACUATED FROM A PATIENT, ADJUSTING THE PUMP SPEED BASED ON THE SENSED INFORMATION, AND COMMUNICATION THE FUNCTION OF THE SYSTEM TO HUB", now U.S. patent application publication No. 2019/0201594;

U.S. patent application Ser. No. 16/209,447, entitled "METHOD FOR SMOKE EVACUTION FOR SURGICAL HUB", now U.S. patent application publication No. 2019/0201045;

U.S. patent application Ser. No. 16/209,453, entitled "METHOD FOR CONTROLLING SMART ENERGY DEVICES", now U.S. patent application publication No. 2019/0201046;

U.S. patent application Ser. No. 16/209,458, entitled "METHOD FOR SMART ENERGY DEVICE FRASTRUCTURURE", now U.S. patent application publication No. 2019/0201047;

U.S. patent application Ser. No. 16/209,465 entitled "METHOD FOR ADAPTIVE CONTROL FOR SURGICAL NETWORK CONTROL AND INTERACTION", now U.S. patent application publication No. 2019/0206563;

U.S. patent application Ser. No. 16/209,478 entitled "METHOD FOR APPARATUS FOR SURGICAL NETWORK OR SURGICAL NETWORK CONNECTED DEVICE OF ADJUNCTIONING FUNCTION ON A SENSED STATIONATION OR USAGE", now U.S. patent application publication No. 2019/0104919;

U.S. patent application Ser. No. 16/209,490, entitled "METHOD FOR FACILITY DATA COLLECTION AND INTERPRETATION", now U.S. patent application publication No. 2019/0206564;

U.S. patent application Ser. No. 16/209,491 entitled "METHOD FOR CIRCULAR STAPLER CONTROL ALGORITHM ADJUSTMENT BASED ON STATIONAL AWARESS", now U.S. patent application publication No. 2019/0200998;

U.S. patent application Ser. No. 16/562,123 entitled "METHOD FOR CONSTRUCTION AND USE A MODULAR SURGICAL ENERGY SYSTEM WITH MULTIPLE DEVICES";

U.S. patent application Ser. No. 16/562,135 entitled "METHOD FOR CONTROLLING AN ENERGY MODULE OUTPUT";

U.S. patent application Ser. No. 16/562,144 entitled "METHOD FOR CONTROLLING A MODULAR ENERGY SYSTEM USER INTERFACE"; and

U.S. patent application Ser. No. 16/562,125, entitled "METHOD FOR COMMUNICATION BETWEEN MODULES AND DEVICES IN A MODULAR SURGICAL SYSTEM".

Before explaining aspects of an electrosurgical system in detail, it should be noted that the illustrative examples are not limited in application or use to the details of construction and arrangement of parts illustrated in the accompanying drawings and description. The illustrative examples may be implemented or incorporated in other aspects, variations and modifications, and may be practiced or carried out in various ways. Furthermore, unless otherwise indicated, the terms and expressions employed herein have been chosen for the purpose of describing the illustrative examples for the convenience of the reader and are not for the purpose of limitation. Moreover, it is to be understood that one or more of the following described aspects, expressions of aspects, and/or examples may be combined with any one or more of the other following described aspects, expressions of aspects, and/or examples.

Various aspects relate to an electrosurgical system of an electrosurgical instrument powered by a generator to effect tissue dissection, cutting and/or coagulation during a surgical procedure. The electrosurgical instrument may be configured for open surgical procedures, but is also applicable to other types of surgical procedures, such as laparoscopic, endoscopic, and robotically-assisted procedures.

As described in detail below, electrosurgical instruments generally include a shaft having a distally mounted end effector (e.g., one or more electrodes). The end effector is positionable against tissue such that an electrical current is introduced into the tissue. The electrosurgical instrument can be configured for bipolar or monopolar operation. During bipolar operation, current is introduced into and returned from the tissue through the active and return electrodes, respectively, of the end effector. During monopolar operation, current is introduced into tissue through the active electrode of the end effector and returned through a return electrode (e.g., a ground pad) separately positioned on the patient's body. The heat generated by the current flowing through the tissue may form a hemostatic seal within and/or between the tissues, and thus may be particularly useful, for example, in sealing blood vessels.

Fig. 1 illustrates an example of a generator 900 configured to deliver multiple energy modalities to a surgical instrument. The generator 900 provides RF signals and/or ultrasonic signals for delivering energy to the surgical instrument. The generator 900 includes at least one generator output that can deliver multiple energy modalities (e.g., ultrasound, bipolar or monopolar RF, irreversible and/or reversible electroporation, and/or microwave energy, etc.) through a single port, and these signals can be delivered separately or simultaneously to the end effector to treat tissue. The generator 900 includes a processor 902 coupled to a waveform generator 904. The processor 902 and waveform generator 904 are configured to be capable of generating a variety of signal waveforms based on information stored in a memory coupled to the processor 902, which memory is not shown for clarity of the present disclosure. Digital information associated with the waveform is provided to a waveform generator 904, which includes one or more DAC circuits to convert a digital input to an analog output. The analog output is fed to an amplifier 906 for useFor signal conditioning and amplification. The regulated and amplified output of amplifier 906 is coupled to power transformer 908. The signal is coupled to the secondary side of the patient isolation side through a power transformer 908. A first signal of a first ENERGY mode is provided to a first ENERGY mode located in a first ENERGY mode labeled ENERGY ₁ And a terminal of the RETURN. A second signal of a second ENERGY mode is coupled across capacitor 910 and provided to a second power supply located at a location labeled ENERGY ₂ And a terminal of the RETURN. It will be appreciated that more than two ENERGY modes may be output, and thus the subscript "n" may be used to specify that up to n ENERGY may be provided _n A terminal, wherein n is a positive integer greater than 1. It should also be understood that up to "n" RETURN paths RETURN may be provided without departing from the scope of this disclosure _n 。

A first voltage sensing circuit 912 is coupled to the first voltage sensing circuit labeled ENERGY ₁ And across the terminals of the RETURN path to measure the output voltage therebetween. A second voltage sense circuit 924 is coupled to the voltage sense circuit labeled ENERGY ₂ And across the terminals of the RETURN path to measure the output voltage therebetween. As shown, a current sensing circuit 914 is placed in series with the RETURN leg on the secondary side of the power transformer 908 to measure the output current of either energy mode. If a different return path is provided for each energy modality, a separate current sensing circuit should be provided in each return branch. The outputs of the first 912 and second 924 voltage sensing circuits are provided to respective isolation transformers 928, 922 and the output of the current sensing circuit 914 is provided to another isolation transformer 916. The outputs of the isolation transformers 916, 928, 922 on the primary side (non-patient isolation side) of the power transformer 908 are provided to one or more ADC circuits 926. The digitized output of the ADC circuit 926 is provided to the processor 902 for further processing and computation. Output voltage and output current feedback information may be employed to adjust the output voltage and current provided to the surgical instrument and calculate parameters such as output impedance. Input/output communication between the processor 902 and the patient isolation circuitry is provided through an interface circuit 920. The sensors may also be in electrical communication with the processor 902 through an interface circuit 920.

In one aspect, the impedance may be determined by the processor 902 by coupling at a coupling labeled ENERGY ₁ First voltage sense circuit 912 coupled across terminals of/RETURN or otherwise labeled ENERGY ₂ The output of the second voltage sense circuit 924 across the terminals of the/RETURN is divided by the output of the current sense circuit 914 provided in series with the RETURN branch on the secondary side of the power transformer 908. The outputs of the first 912 and second 924 voltage sensing circuits are provided to separate isolation transformers 928, 922 and the output of the current sensing circuit 914 is provided to another isolation transformer 916. The digitized voltage and current sense measurements from the ADC circuit 926 are provided to the processor 902 for use in calculating the impedance. For example, the first ENERGY modality ENERGY ₁ May be RF monopole ENERGY, and a second ENERGY modality ENERGY ₂ May be RF bipolar energy. However, in addition to bipolar and monopolar RF energy modalities, other energy modalities include ultrasound energy, irreversible and/or reversible electroporation, and/or microwave energy, among others. Also, while the example shown in fig. 1 shows that a single RETURN path RETURN may be provided for two or more ENERGY modalities, in other aspects, a single RETURN path RETURN may be provided for each ENERGY modality ENERGY _n Providing multiple RETURN paths RETURN _n 。

As shown in fig. 1, the generator 900 including at least one output port may include a power transformer 908 having a single output and multiple taps to provide power to the end effector in the form of one or more energy modalities (such as ultrasound, bipolar or monopolar RF, irreversible and/or reversible electroporation, and/or microwave energy, etc.), for example, depending on the type of tissue treatment being performed. For example, the generator 900 may deliver energy with higher voltages and lower currents to drive an ultrasound transducer, with lower voltages and higher currents to drive an RF electrode for sealing tissue, or with a coagulation waveform for spot coagulation using monopolar or bipolar RF electrosurgical electrodes. The output waveform from the generator 900 may be manipulated, switched, or filtered to provide a frequency to the end effector of the surgical instrument. In one example, the connection of the RF bipolar electrode to the output of the generator 900 will preferably be located at the targetIs recorded as ENERGY ₂ And the output of RETURN. In the case of a single pole output, the preferred connection would be ENERGY ₂ An active electrode (e.g., a pencil or other probe) at the output and a suitable RETURN pad connected to the RETURN output.

Additional details are disclosed in U.S. patent application publication 2017/0086914 entitled "TECHNIQUES FOR OPERATING GENERATOR FOR DIGITALLY GENERATING ELECTRICAL SIGNAL WAVEFORMS AND SURGICAL INSTRUMENTS," published 3, 30, 2017, which is incorporated herein by reference in its entirety.

Fig. 2 illustrates one form of a surgical system 1000 including a generator 1100 and various surgical instruments 1104, 1106, 1108 that can be used therewith, wherein the surgical instrument 1104 is an ultrasonic surgical instrument, the surgical instrument 1106 is an RF electrosurgical instrument, and the multifunctional surgical instrument 1108 is a combination ultrasonic/RF electrosurgical instrument. The generator 1100 may be configured for use with a variety of surgical devices. According to various forms, the generator 1100 may be configurable for use with different types of surgical instruments, including, for example, an ultrasonic surgical instrument 1104, an RF electrosurgical instrument 1106, and a multifunctional surgical instrument 1108 that integrates both RF energy and ultrasonic energy delivered simultaneously from the generator 1100. Although in the form of fig. 2, the generator 1100 is shown as being separate from the surgical instruments 1104, 1106, 1108, in one form, the generator 1100 may be integrally formed with any of the surgical instruments 1104, 1106, 1108 to form an integrated surgical system. The generator 1100 includes an input device 1110 located on the front panel of the console of the generator 1100. Input device 1110 may include any suitable device that generates signals suitable for programming the operation of generator 1100. Generator 1100 may be configured for wired or wireless communication.

The generator 1100 is configured to drive a plurality of surgical instruments 1104, 1106, 1108. The first surgical instrument is an ultrasonic surgical instrument 1104 and includes a handpiece 1105(HP), an ultrasonic transducer 1120, a shaft 1126, and an end effector 1122. The end effector 1122 includes an ultrasonic blade 1128 and a clamp arm 1140 acoustically coupled to an ultrasonic transducer 1120. The handpiece 1105 includes a combination of a trigger 1143 for operating the clamp arm 1140 and toggle buttons 1137, 1134b, 1134c for energizing the ultrasonic blade 1128 and driving the ultrasonic blade or other functions. The toggle buttons 1137, 1134b, 1134c may be configured to enable the generator 1100 to power the ultrasound transducer 1120.

The generator 1100 is also configured to drive a second surgical instrument 1106. The second surgical instrument 1106 is an RF electrosurgical instrument and includes a handpiece 1107(HP), a shaft 1127, and an end effector 1124. The end effector 1124 includes electrodes in the clamp arms 1145, 1142b and returns through the electrical conductor portion of the shaft 1127. The electrodes are coupled to and powered by a bipolar energy source within the generator 1100. The handpiece 1107 includes a trigger 1145 for operating the grip arms 1145, 1142b and an energy button 1135 for actuating an energy switch to energize the electrodes in the end effector 1124. The second surgical instrument 1106 may also be used with a return pad to deliver monopolar energy to tissue.

The generator 1100 is also configured to drive a multi-function surgical instrument 1108. The multifunctional surgical instrument 1108 includes a hand piece 1109(HP), a shaft 1129, and an end effector 1125. The end effector 1125 includes an ultrasonic blade 1149 and a clamp arm 1146. The ultrasonic blade 1149 is acoustically coupled to the ultrasonic transducer 1120. The handpiece 1109 includes a combination of a trigger 1147 for operating the clamp arm 1146 and toggle buttons 11310, 1137b, 1137c for energizing the ultrasonic blade 1149 and driving the ultrasonic blade or other functions. The toggle buttons 11310, 1137b, 1137c may be configured to enable the generator 1100 to power the ultrasonic transducer 1120, and the bipolar energy source also housed within the generator 1100 to power the ultrasonic blade 1149. Monopolar energy may be delivered to the tissue in combination with or separately from bipolar energy.

The generator 1100 may be configured for use with a variety of surgical devices. According to various forms, the generator 1100 may be configurable for use with different types of surgical instruments including, for example, an ultrasonic surgical instrument 1104, an RF electrosurgical instrument 1106, and a multifunctional surgical instrument 1108 that integrates both RF energy and ultrasonic energy delivered simultaneously from the generator 1100. While in the form of fig. 2, the generator 1100 is shown as being independent of the surgical instruments 1104, 1106, 1108, in another form, the generator 1100 may be integrally formed with any of the surgical instruments 1104, 1106, 1108 to form an integrated surgical system. As discussed above, the generator 1100 includes an input device 1110 located on the front panel of the console of the generator 1100. Input device 1110 may include any suitable device that generates signals suitable for programming the operation of generator 1100. The generator 1100 may also include one or more output devices 1112. Additional aspects of generators and surgical instruments for digitally generating electrical signal waveforms are described in U.S. patent application publication US-2017-0086914-a1, which is incorporated by reference herein in its entirety.

Fig. 3 shows a schematic view of a surgical instrument or tool 600 including multiple motor assemblies that can be actuated to perform various functions. In the illustrated example, the closure motor assembly 610 is operable to transition the end effector between an open configuration and a closed configuration, and the articulation motor assembly 620 is operable to articulate the end effector relative to the shaft assembly. In some instances, multiple motor assemblies may be individually activated to induce firing, closing, and/or articulation motions in the end effector. Firing motions, closing motions, and/or articulation motions can be transmitted to the end effector, for example, by a shaft assembly.

In some cases, the closure motor assembly 610 includes a closure motor. The closure member 603 is operably coupled to a closure motor drive assembly 612, which may be configured to transmit the closure motion generated by the motor to the end effector, in particular to displace the closure member to close, thereby transitioning the end effector to a closed configuration. The closing motion can transition the end effector from an open configuration to a closed configuration, e.g., to capture tissue. The end effector may be transitioned to the open position by reversing the direction of the motor.

In some instances, the articulation motor assembly 620 comprises an articulation motor operably coupled to an articulation drive assembly 622, which may be configured to transmit articulation motions generated by the motor to the end effector. In some cases, the articulation can articulate the end effector relative to the shaft, for example.

One or more of the motors of the surgical instrument 600 may include a torque sensor to measure the output torque on the motor shaft. The force on the end effector can be sensed in any conventional manner, such as by a force sensor on the outside of the jaws or by a torque sensor of a motor used to actuate the jaws.

In various instances, the motor assemblies 610, 620 include one or more motor drivers, which may include one or more H-bridge FETs. The motor driver may regulate the power delivered to the motor from the power source 630, for example, based on input from a microcontroller 640 ("controller"), e.g., control circuit 601. In some cases, for example, microcontroller 640 may be used to determine the current drawn by the motor.

In some cases, microcontroller 640 may include a microprocessor 642 ("processor") and one or more non-transitory computer-readable media or storage units 644 ("memory"). In some cases, memory 644 may store various program instructions that, when executed, may cause processor 642 to perform various functions and/or computations described herein. In some cases, one or more of memory units 644 may be coupled to processor 642, for example. In various aspects, microcontroller 640 may communicate over a wired or wireless channel, or a combination thereof.

In some cases, power source 630 may be used, for example, to supply power to microcontroller 640. In some cases, the power source 630 may include a battery (or "battery pack" or "power pack"), such as, for example, a lithium ion battery. In some cases, the battery pack may be configured to be releasably mountable to the handle for supplying power to the surgical instrument 600. A plurality of series-connected battery cells may be used as the power source 630. In some cases, power source 630 may be replaceable and/or rechargeable, for example.

In various instances, the processor 642 may control the motor driver to control the position, rotational direction, and/or speed of the motors of the components 610, 620. In some cases, the processor 642 may signal the motor driver to stop and/or disable the motor. It is to be understood that the term "processor" as used herein includes any suitable microprocessor, microcontroller, or other basic computing device that combines the functions of a computer's Central Processing Unit (CPU) on one integrated circuit or at most several integrated circuits. Processor 642 is a multipurpose programmable device that receives digital data as input, processes the input according to instructions stored in its memory, and then provides the result as output. Because the processor has internal memory, it is an example of sequential digital logic. The operands of the processor are numbers and symbols represented in a binary numerical system.

In one case, processor 642 may be any single-core or multi-core processor, such as those known under the trade name ARM Cortex, manufactured by Texas Instruments. In some cases, microcontroller 620 may be, for example, LM4F230H5QR, available from Texas Instruments. In at least one example, the Texas Instruments LM4F230H5QR is an ARM Cortex-M4F processor core that includes: 256KB on-chip memory of Single-cycle flash or other non-volatile memory (up to 40MHz), prefetch buffers to improve performance above 40MHz, 32KB Single-cycle SRAM, Stellaris loaded

Internal ROM of software, EEPROM of 2KB, one or more PWM modules, one or more QEI analog, one or more 12-bit ADC with 12 analog input channels, and other features readily available. Other microcontrollers could be readily substituted for use with surgical instrument 600. Accordingly, the present disclosure should not be limited to this context.

In some cases, memory 644 may include program instructions for controlling each of the motors of surgical instrument 600. For example, the memory 644 may include program instructions for controlling the closure motor and the articulation motor. Such program instructions may cause the processor 642 to control the closure and articulation functions in accordance with input from an algorithm or control program of the surgical instrument 600.

In some cases, one or more mechanisms and/or sensors, such as sensor 645, may be employed to alert processor 642 to program instructions that should be used in a particular setting. For example, the sensor 645 may alert the processor 642 to use program instructions associated with closing and articulating the end effector. In some cases, sensor 645 may include, for example, a position sensor that may be used to sense the position of the closure actuator. Thus, if the processor 642 receives a signal from the sensor 630 indicative of actuation of the closure actuator, the processor 642 may actuate the motor of the closure drive assembly 620 using program instructions associated with the closure end effector.

In some examples, the motor may be a brushless DC electric motor, and the respective motor drive signals may include PWM signals provided to one or more stator windings of the motor. Also, in some examples, the motor driver may be omitted and the control circuit 601 may directly generate the motor drive signal.

During various laparoscopic surgical procedures, it is common practice to insert a surgical end effector portion of a surgical instrument through a trocar that has been installed in a patient's abdominal wall to access a surgical site located within the patient's abdomen. The simplest form of trocar is a pen-shaped instrument with a sharp triangular point at one end, which is typically used inside a hollow tube called a conduit or sleeve to create an opening into the body through which a surgical end effector can be introduced. This arrangement creates an access port into the body cavity through which the surgical end effector can be inserted. The inner diameter of the trocar tube necessarily limits the size of the end effector and drive support shaft of a surgical instrument that can be inserted through the trocar.

Regardless of the particular type of surgical procedure being performed, once the surgical end effector has been inserted into the patient through the trocar tube, the surgical end effector must typically be moved relative to a shaft assembly positioned within the trocar tube in order to properly position the surgical end effector relative to the tissue or organ to be treated. This movement or positioning of the surgical end effector relative to the shaft portion retained within the trocar tube is commonly referred to as "articulation" of the surgical end effector. A variety of articulation joints have been developed to attach a surgical end effector to an associated shaft to facilitate such articulation of the surgical end effector. It is contemplated that in many surgical procedures, it is desirable to employ a surgical end effector having as large a range of articulation as possible.

Due to the size constraints imposed by the size of the trocar tube, the size of the articulation joint components must facilitate free insertion through the trocar tube. These dimensional constraints also limit the size and composition of the various drive components and components that operatively interact with the motor and/or other control systems supported in a housing that may be hand-held or comprise part of a larger automated system. In many instances, these drive members must operatively pass through the articulation joint to operatively couple to or operatively interact with the surgical end effector. For example, one such drive member is commonly used to apply articulation control motions to a surgical end effector. During use, the articulation drive member may not be actuated to position the surgical end effector in an unarticulated position to facilitate insertion of the surgical end effector through the trocar and then actuated to articulate the surgical end effector to a desired position once the surgical end effector is inside a patient.

Accordingly, the above-described size constraints present a number of challenges for developing an articulation system that can achieve a desired range of articulation and also accommodate the variety of different drive systems required to operate the various features of the surgical end effector. Further, once the surgical end effector has been positioned in a desired articulation position, the articulation system and articulation joint must be capable of maintaining the surgical end effector in that position during actuation of the end effector and completion of a surgical procedure. Such an articulation joint arrangement must also be able to withstand external forces experienced by the end effector during use.

Fig. 4-7 illustrate an electrosurgical instrument 30100 that includes a first jaw 30110, a second jaw 30120, and a monopolar wedge electrode 30130. The first and second jaws 30110, 30120 are movable between an open position and a closed position and are configured to grasp tissue T located between the first and second jaws. Each of the first and second jaws 30110 and 30120 includes an electrode electrically coupled to a power generator. Exemplary suitable power generators 900, 1100 are described above in connection with fig. 1 and 2. The power generator is configured to supply power to cause the electrodes of the first and second jaws 30110 and 30120 to cooperatively deliver bipolar energy to grasped tissue to seal, coagulate, and/or cauterize tissue in a bipolar tissue treatment cycle.

In use, when tissue T is grasped between the first and second jaws 30110, 30120, the first and second jaws may deflect away from each other at their distal ends. When grasping tissue T, the tissue T applies a force to the first and second jaws 30110 and 30120, causing the jaws to deflect away from each other. More specifically, when tissue T is grasped between the first and second jaws 30110, 30120, a gap B between the first and second jaws 30110, 30120 toward a distal end of the jaws may be greater than a gap a between the first and second jaws 30110, 30120 toward a proximal end of the jaws.

In addition to the above, the end effector 30100 of the electrosurgical instrument 30100 further includes a monopolar wedge electrode 30130 electrically connected to a power generator (e.g., power generators 900, 1100) and configured to cut tissue T positioned between the first jaw 30110 and the second jaw 30120 when energized by the power generator. In the illustrated embodiment, a monopolar wedge electrode 30130 is attached to the second jaw 30120; however, other embodiments are contemplated in which a monopolar wedge electrode 30130 is attached to the first jaw 30110. The monopolar wedge electrode 30130 is thinner at its proximal end and thicker at its distal end (see fig. 7) to compensate for the variable gap defined between the first jaw 30110 and the second jaw 30120. In other words, the monopolar wedge electrode 30130 has a wedge shape. As previously described, the variable gap defined between the jaws 30110, 30120 is due, at least in part, to deflection of the jaws 30110, 30120 as tissue is grasped therebetween. In at least one embodiment, the monopolar wedge electrode 30130 includes a compliant flex circuit substrate 30132. The compliant flex circuit substrate 30132 is configured to bend and/or flex longitudinally to compensate for flexing of the first and second jaws 30110, 30120 when tissue is grasped between the first and second jaws 30110, 30120.

In various examples, the monopolar wedge electrode 30130 includes a conductive member 30134 centrally disposed along the length of the compliant flex circuit substrate 30132. In the illustrated example, the conductive members 30134 are disposed on the compliant flex circuit substrate 30132, with at least a portion of the conductive members exposed through a top surface of the compliant flex circuit substrate 30132. In some examples, portions of the conductive members 30134 are exposed, while other portions are covered by the compliant flex circuit substrate 30132.

In examples where the jaws 30110, 30120 include curved shapes, the monopolar wedge electrode 30130 extends longitudinally with a similar curved profile. In addition, the monopolar wedge electrode 30130 tapers from a larger width to a smaller width as it extends longitudinally. Thus, the monopolar wedge electrode 30130 has a first width proximate its proximal end that is greater than a second width proximate its distal end, as shown in fig. 6. In other examples, a first width of the monopolar wedge electrode proximate its proximal end may be less than a second width proximate its distal end.

In the illustrated example, the distal ends of the conductive elements 30134 are proximal to the distal ends of the compliant flex circuit substrate 30132, and the distal ends of the compliant flex circuit substrate 30132 are proximal to the distal ends of the jaws 30130. However, in other examples, the jaws 30130, the conductive members 30134, and the distal ends of the compliant flex circuit substrate 30132 are joined at one location.

Fig. 8-10 illustrate an electrosurgical instrument 30200 including a first jaw 30210, a second jaw 30220, and a monopolar electrode 30230. The first and second jaws 30210 and 30220 are movable between an open position and a closed position wherein tissue is configured to be positioned therebetween. The first jaw 30210 and the second jaw 30220 are comprised of metal and may be coated with a dielectric material. In at least one embodiment, the first jaw 30210 and the second jaw 30220 are constructed of stainless steel and coated with a shrink tube. In various aspects, the jaws 30210, 30220 define a bipolar electrode that is electrically isolated from the monopolar electrode 30230.

The first jaw 30210 includes a first flexible member 30240 positioned about the first jaw 30210, and the second jaw 30220 includes a second flexible member 30250 positioned about the second jaw 30220. The compliant members 30240, 30250 comprise a deformable dielectric material that is compressible to enhance contact with tissue when tissue is positioned between the first jaw 30210 and the second jaw 30220. In at least one embodiment, the compliant members 30240, 30250 include silicone and/or rubber.

In addition to the above, when the monopolar electrode 30230 is energized by a power generator (e.g., generators 1100, 900), the monopolar electrode 30230 is used to cut tissue positioned between the first jaw 30210 and the second jaw 30220. The monopolar electrode 30230 includes a wire extending along the first jaw 30210 and into the first compliant member 30240. The monopolar electrode 30230 exits the first flexible member 20140 through the proximal opening 30242 in the first flexible member 30240, extends along the exterior of the first flexible member 30240, and then re-enters the first flexible member 20140 through the distal opening 30244 in the first flexible member 30240. This arrangement allows the central portion 30232 of the monopolar electrode 30230 to bend and/or flex when tissue is grasped between the first jaw 30210 and the second jaw 30220. In addition, the first compliant member 30240 reinforces the central portion 30232 of the monopolar electrode 30230 along its length. In other words, the first compliant member 30240 applies a biasing force to the central portion 30232 of the monopolar electrode 30230 toward the second jaw 30220. When the first and second jaws 30210, 30220 grasp tissue positioned between the first and second jaws, the first compliant member 30240 increases the pressure exerted by the monopolar electrode 30230 on the tissue to increase the cutting capacity of the monopolar electrode 30230.

In various aspects, the monopolar electrode 30230 may be comprised of a metal such as, for example, stainless steel, titanium, or any other suitable metal. The exposed surface of monopolar electrode 30230 may have a bare metallic appearance or may be coated with a thin dielectric material such as, for example, PTFE. In various aspects, the coating may be shaved to expose a thin metal strip defining the conductive surface.

Fig. 11 illustrates a surgical instrument 30300 that includes a first jaw 30310, a second jaw 30320, and a monopolar electrode 30330. The first jaw 30310 and the second jaw 30320 are movable between an open position and a closed position to grasp tissue T located between the first jaw and the second jaw. The first jaw 30310 includes a first bipolar electrode and the second jaw 30320 includes a second bipolar electrode. The first bipolar electrode and the second bipolar electrode cooperate to deliver bipolar energy to cauterize and/or seal tissue grasped between the first jaw 30310 and the second jaw 30320 during a bipolar tissue treatment cycle.

In addition to the above, the first jaw 30310 includes a first tissue contacting surface 30314 and the second jaw 30320 includes a second tissue contacting surface 30324. The first jaw 30310 includes a first recess 30312 configured to receive a first compliant or biasing member 30340 therein. The first biasing member 30340 is configured to bias the tissue T toward the second jaw 30320 when the tissue T is grasped between the first and second jaws 30310, 30320. The second jaw includes a second recess 30322 configured to receive a second compliant or biasing member 30350 and a monopolar electrode 30330 therein. The second biasing member 30350 is configured to bias the monopolar electrode 30330 and the tissue T toward the first jaw 30310 when the tissue T is grasped between the first jaw 30310 and the second jaw 30320.

In addition to the above, the first and second recesses 30312, 30322 are sized and shaped to receive the first and second biasing members 30340, 30350 and the monopolar electrode 30330 to ensure that the first and second jaws 30310, 30320 can be fully closed. In other words, when the first and second jaws 30310, 30320 are in the closed position, the first and second tissue contacting surfaces 30314, 30324 contact each other when no tissue T is positioned therebetween. However, other embodiments are contemplated wherein a gap is defined between the first tissue contacting surface 30314 and the second tissue contacting surface 30324 when the tissue T is positioned therebetween and/or when the tissue T is not positioned therebetween when the first and second jaws 30310, 30320 are in the closed position. In any event, the first and second recesses 30312, 30322 are sized and/or shaped such that the monopolar electrode 30330 extends over the second tissue contacting surface 30324 and into the first recess 30312 of the first jaw 30310 to improve the ability of the first and second jaws 30310, 30320 to close fully. The first and second recesses 30312, 30322 include an electrically isolating material to electrically isolate the monopolar electrode 30330 from the first and second jaws 30310, 30320. However, other embodiments are contemplated in which the first and second recesses 30312, 30322 do not electrically isolate the monopolar electrode 30330 from the first and second jaws 30310, 30320. Monopolar electrode 30330 includes a separate wired connection to the control housing of the surgical instrument 30300. This independent wire connection allows the monopolar electrode 30330 to be energized independently of the first and second electrodes of the first and second jaws 30310, 30320, thereby enabling cutting and/or sealing operations to be performed independently of one another. In at least one embodiment, the control housing of the surgical instrument 30300 prevents the monopolar electrodes 30330 from being energized until the first and second electrodes of the first and second jaws 30310 and 30320 are energized to prevent cutting of tissue T that has not been cauterized and/or sealed.

Fig. 12 illustrates a surgical end effector 30400 for use with an electrosurgical instrument. The end effector 30400 includes a first jaw having a first bipolar electrode 30410, a second jaw having a second bipolar electrode 30420, and a monopolar electrode 30430. The first bipolar electrode 30410 and the second bipolar electrode 30420 are at least partially surrounded by a compliant member and/or compliant insulator 30440. The compliant insulator 30440 can include rubber, silicone, Polytetrafluoroethylene (PTFE) tubing, and/or combinations thereof. A monopolar electrode 30430 is attached to the compliant insulator 30440 of the first bipolar electrode 30410. Thus, the unipolar electrode 30430 is electrically insulated from the first bipolar electrode 30410. In at least one embodiment, the compliant insulator 30440 surrounding the first electrode 30410 comprises a rigid or at least substantially rigid PTFE tube, and the second compliant insulator 30440 surrounding the second electrode 30420 comprises a silicone and/or rubber material. For example, other embodiments are contemplated having different combinations of PTFE tubing, rubber, and/or silicone positioned at least partially around the first bipolar electrode 30410 and the second bipolar electrode 30420.

Fig. 13 illustrates a surgical end effector 30500 for use with an electrosurgical instrument. The surgical end effector includes a first jaw 30510 and a second jaw 30520 movable between an open position and a closed position to grasp tissue positioned between the first jaw and the second jaw. The first jaw 30510 is at least partially surrounded by the first flexible member 30514, and the second jaw 30520 is at least partially surrounded by the second flexible member 30524. The first flexible member 30514 is almost completely surrounded by the first bipolar electrode 30512, and the second flexible member 30524 is almost completely surrounded by the second bipolar electrode 30522. More specifically, first bipolar electrode 30512 surrounds first flexible member 30514 except for gap portion 30516, where monopolar electrode 30530 is affixed to first flexible member 30514. Further, the second bipolar electrode 30522 surrounds the second compliant member 30524 except for a gap portion 30526 facing the first jaw 30510. A gap portion 30526 in the second jaw 30520 allows the monopolar electrode 30530 extending from the first flexible member 30514 to experience a biasing force from the first and second flexible members 30514, 30524 when the first and second jaws 30510, 30520 grasp tissue in the closed position. First and second flexible members 30514, 30524 comprise an electrically insulating material to electrically isolate the unipolar electrode 30530 from the first and second bipolar electrodes 30512, 30522. First and second flexible members 30514, 30524 may comprise rubber, silicone, PTFE tubing, and/or combinations thereof.

FIG. 14 illustrates a surgical end effector 30600 for use with an electrosurgical instrument. The surgical end effector 30600 includes a first jaw 30610 and a second jaw 30620 that are movable between an open position and a closed position to grasp tissue positioned between the first and second jaws. The first jaw 30610 is at least partially surrounded by a first flexible member 30614, and the second jaw 30620 is at least partially surrounded by a second flexible member 30624. First compliant member 30614 is almost completely surrounded by first bipolar electrode 30612, and second compliant member 30624 is almost completely surrounded by second bipolar electrode 30622. In other words, first bipolar electrode 30612 encircles first compliant member 30614 except for gap portion 30616, where unipolar electrode 30630 is attached to first compliant member 30614. Further, a second bipolar electrode 30622 surrounds second compliant member 30624, except for gap 30626.

In addition to the above, when the first jaw 30610 and the second jaw 30620 are in a closed position, gap portions 30616, 30626 in the first bipolar electrode 30612 and the second bipolar electrode 30622 allow the unipolar electrode 30630 extending from the first compliant member 30614 to contact the second compliant member 30624. Further, when the jaws 30610, 30620 are closed with no tissue positioned therebetween, the gap portions 30616, 30626 are offset to allow the first bipolar electrode 30612 to contact the second compliant member 30624 and to allow the second bipolar electrode 30622 to contact the first compliant member 30614. Unlike the electrodes 30512, 30533, the electrodes 30612, 30622 are not mirror images of each other. In contrast, the electrode 30612 is offset from the electrode 30622, causing the gap portions 30616, 30610 to also be offset from each other. This arrangement prevents the circuit from being short-circuited.

In any case, when the first and second jaws 30610, 30620 are closed, the unipolar electrode 30630 is positioned between the first and second compliant members 30614, 30624 to provide a spring or biasing force to the unipolar electrode 30630 as tissue is grasped between the jaws 30610, 30620. In other words, as first jaw 30610 and second jaw 30620 close around tissue, unipolar electrode 30630 experiences a biasing force from first and second compliant members 30614, 30624. When the monopolar electrode 30630 is energized, the biasing force from the compliant members 30614, 30624 facilitates tissue cutting.

In addition to the above, in at least one embodiment, first and second flexible members 30614, 30624 include an electrically insulating material to electrically isolate unipolar electrode 30630 from first and second bipolar electrodes 30612, 30622. In at least one embodiment, first and second compliant members 30614, 30624 may include rubber, silicone, PTFE tubing, and/or combinations thereof.

Fig. 15 illustrates a surgical end effector 30700 for use with an electrosurgical instrument. The end effector 30700 includes a first jaw 30710 and a second jaw 30720 that are movable between an open position and a closed position to grasp tissue positioned between the first and second jaws. The first jaw 30710 defines a first bipolar electrode and the second jaw 30720 defines a second bipolar electrode configured to cooperate to deliver bipolar energy to cauterize and/or seal tissue grasped between the first and second jaws 30710, 30720. Further, the first jaw 30710 includes a first longitudinal recess 30712 including a first compliant member 30714 attached therein. The second jaw 30720 includes a second longitudinal recess 30722 that includes a second compliant member 30724 attached therein. The surgical end effector 30700 also includes a monopolar electrode 30730 attached to the first compliant member 30714. The gap portions 30714 in the second compliant member 30724 allow the monopolar electrodes 30730 extending from the first compliant member 30714 to experience a biasing force from the first and second compliant members 30714 and 30724 when the first and second jaws 30710 and 30720 grasp tissue in a closed position. The first and second compliant members 30714 and 30724 include an electrically insulating material to electrically isolate the monopolar electrode 30730 from the first electrode of the first jaw 30710 and the second electrode of the second jaw 30720. First and second compliant members 30714 and 30724 may comprise rubber, silicone, PTFE tubing, and/or combinations thereof.

FIG. 16 illustrates a surgical end effector for use with an electrosurgical instrument. The end effector 30800 includes a first jaw 30810 and a second jaw 30820 movable between an open position and a closed position to grasp tissue positioned between the first and second jaws. The first jaw 30810 defines a first bipolar electrode and the second jaw 30820 defines a second bipolar electrode. As described above, the first and second bipolar electrodes are configured to cooperate to deliver bipolar energy to cauterize and/or seal tissue positioned between the first and second jaws 30810, 30820. Further, the first jaw 30810 includes a longitudinal recess 30812 that includes a compliant member 30814 attached therein. In at least one embodiment, the second jaw 30820 comprises stainless steel coated with a PTFE shrink tube. The surgical end effector 30800 also includes a monopolar electrode 30830 attached to the compliant member 30814 of the first jaw 30810. The compliant member 30814 provides a biasing force to the monopolar electrode 30830 when the first and second jaws 30810, 30820 grasp tissue located therebetween. The biasing force of the compliant member 30814 enhances contact between the monopolar electrode 30830 and tissue during a cutting operation. Compliant member 30814 includes an electrically insulating material to electrically isolate the monopolar electrode 30830 from the first electrode of the first jaw 30810. The compliant member 30814 may include rubber, silicone, PTFE tubing, and/or combinations thereof.

Fig. 17 shows an alternative surgical end effector 30800' to the surgical end effector 30800. The end effector 30800' is similar to the end effector 30800; however, a monopolar electrode 30830 is attached to the second jaw 30820. The compliant member 30814 applies a biasing force through the tissue to the monopolar electrode 30830 attached to the second jaw 30820 when the tissue is positioned between the first jaw 30810 and the second jaw 30820.

Fig. 18 illustrates a surgical end effector 30900 for use with an electrosurgical instrument. The surgical end effector 30900 defines an end effector axis EA that extends longitudinally along the length of the end effector 30900. The surgical end effector 30900 includes a first jaw 30910 and a second jaw 30920 that are movable between an open position and a closed position to grasp tissue positioned between the first and second jaws. The first jaw 30910 includes a first honeycomb grid structure 30912 surrounded by a first diamond-like coating 30914. The second jaw 30920 includes a second honeycomb grid structure 30922 surrounded by a second diamond-like coating 30924. The diamond- like coating 30914, 30924 can be, for example, any of the diamond-like coatings described herein. The first honeycomb cell structure 30912 and the second honeycomb cell structure 30922 include the same geometric array and material. However, other embodiments are contemplated in which the first and second honeycomb cell structures 30912, 30922 include different geometric arrays and materials including more or less air pockets, as described herein. The first type of diamond coating 30914 and the second type of diamond coating 30924 comprise the same material. However, other embodiments are contemplated in which the first type of diamond coating 30914 and the second type of diamond coating 30924 include different materials.

In addition to the above, the end effector 30900 also includes a first bipolar electrode 30940 of a first diamond-like coating 30914 attached to the first jaw 30910 on a first lateral side of the end effector axis EA. The first bipolar electrode 30940 extends longitudinally along the length of the end effector 30900. Second jaw 30920 includes a compliant member 30960 attached within a cutout portion 30926 defined in second jaw 30920. End effector 30900 also includes a second bipolar electrode 30950 attached to compliant member 30960 on a second lateral side of end effector axis EA. The second bipolar electrode 30950 extends longitudinally along the length of the end effector 30900. Electrodes 30940, 30950 cooperate to deliver bipolar energy to tissue grasped between jaws 30910, 30920. In addition, the electrodes 30940, 30950 are offset from each other to prevent accidental contact between them in the closed position, which may form a short circuit.

In addition, the end effector 30900 includes a monopolar electrode 30930 attached to the compliant member 30960 and positioned intermediate a first bipolar electrode 30940 and a second bipolar electrode 30950. The monopolar electrode 30930 extends longitudinally along the length of the end effector 30900 and, in at least one embodiment, is aligned with the end effector axis EA.

As described herein, the first bipolar electrode 30940 and the second bipolar electrode 30950 are configured to cauterize and/or seal tissue by delivering bipolar energy to the tissue in a bipolar energy cycle when the tissue is positioned between the first jaw 30910 and the second jaw 30920. Further, the monopolar electrode 30930 is configured to be capable of cutting tissue by delivering monopolar energy to the tissue in a monopolar energy cycle.

In addition to the above, compliant member 30960 is compressible and applies pressure to tissue positioned between first jaw 30910 and second jaw 30920. More specifically, the pressure exerted by jaws 30910, 30920 on tissue in the region directly above compliant member 30960 is greater than the pressure exerted on tissue in the region adjacent to compliant member 30960 (i.e., the region where there is no compliant member 30960). In at least one embodiment, compliant member 30960 includes an elastic and/or plastic honeycomb structure that insulates second bipolar electrode 30950 and monopolar electrode 30930 from second diamond-like coating 30924 and honeycomb grid structure 30922 of second jaw 30920. The compliant member 30960 holds the second bipolar electrode 30950 and the monopolar electrode 30930 in place and provides a biasing force to the monopolar electrode 30930 and the second bipolar electrode 30950 toward the first jaw 30910 as tissue is grasped between the first jaw 30910 and the second jaw 30920.

In addition to the above, the first diamond coating 30914 and the second diamond-like coating 30924 are electrically and thermally conductive. However, other embodiments are contemplated in which the first diamond coating 30914 and the second diamond-like coating 30924 are electrically and/or thermally insulating. The first and second honeycomb grid structures 30912, 30922 include air pockets that provide thermal insulation for the first and second jaws 30910, 30920. The first and second honeycomb lattice structures 30912, 30922 provide additional spring bias to tissue when tissue is positioned between the first and second jaws 30910, 30920. In at least one embodiment, the first and second honeycomb structures 30912, 30922 allow the first and second jaws 30910, 30920 to flex and/or bend when tissue is grasped therebetween. In any event, the spring forces of first and second honeycomb grid structures 30912, 30922 and compliant member 30960 provide consistent pressure to the tissue as it is grasped between first and second jaws 30910, 30920.

In various aspects, one or more of the diamond-like coatings (DLC)30914, 30924 are composed of an amorphous carbon-hydrogen network with graphitic and diamond bonding between carbon atoms. The DLC coatings 30914, 30924 can form a film with low friction and high hardness properties around the first and second honeycomb grid structures 30912, 30922. The DLC coatings 30914, 30924 may be doped or undoped, and are generally in the form of amorphous carbon (a-C) or hydrogenated amorphous carbon (a-C: H) containing a significant number of sp3 bonds. Various surface coating techniques may be used to form the DLC coatings 30914, 30924, such as those developed by Oerlikon Balzers. In at least one example, DLC coatings 30914, 30924 are generated using Plasma Assisted Chemical Vapor Deposition (PACVD).

In various aspects, one or both of the DLC coatings can comprise titanium nitride, chromium nitride, graphiit iC ^TM Or any other suitable coating.

Still referring to fig. 18, the electrodes 30940, 30950 are offset such that a plane extending along the axis EA and transverse to the monopolar electrode 30930 extends between the electrodes 30940, 30950. Further, in the illustrated example, electrodes 30930, 30940, 30950 protrude from the outer surface of jaws 30910, 30920. However, in other examples, one or more of electrodes 30930, 30940, 30950 may be embedded in jaws 30910, 30920 such that their outer surfaces are flush with the outer surfaces of jaws 30910, 30920.

The plurality of end effectors described in connection with fig. 4-18 are configured to coagulate, cauterize, seal, and/or cut tissue grasped by the end effectors during a tissue treatment cycle that includes delivering bipolar and/or monopolar energy to the tissue. Bipolar energy and monopolar energy may be delivered to the tissue separately or in combination. In one example, monopolar energy is delivered to the tissue after bipolar energy delivery to the tissue is terminated.

Fig. 19 is a graph depicting an alternative example of a tissue treatment cycle 31000 delivering bipolar energy (in a bipolar energy cycle) and monopolar energy (in a monopolar energy cycle) to tissue. The tissue treatment cycle 31000 includes a bipolar-only phase 31002, a mixed energy phase 31004, and a monopolar-only phase 31006. The tissue treatment cycle 31000 can be implemented by an electrosurgical system including a generator (e.g., generators 1100, 900) coupled to an electrosurgical instrument, for example, including an end effector (e.g., the end effector of fig. 4-18).

The graph of fig. 19 depicts power (W) on the y-axis and time on the x-axis. The power values provided in this graph and in the following description are non-limiting examples of power levels that may be used with tissue treatment cycle 31000. Other suitable power levels are contemplated by the present disclosure. The graph depicts a bipolar power curve 31010 and a unipolar power curve 31014. Further, the hybrid power curve 31012 represents the simultaneous application of monopolar and bipolar energy to the tissue.

Still referring to FIG. 19, the initial tissue contact phase is shown at t ₀ And t ₁ Before any energy is applied to the tissue. The jaws of the end effector are positioned on opposite sides of the tissue to be treated. Then at the beginning of t ₁ And ends at t ₄ Applying bipolar energy to the tissue throughout the tissue coagulation phase. In the eclosion section (t) ₁ -t ₂ ) During this period, the bipolar energy application is increased to a predetermined power value (e.g., 100W), and in the emergence zone (t) ₁ -t ₂ ) And the remaining part of the tissue warming segment (t) ₂ -t ₃ ) During which time it is maintained at the predetermined power value. In the sealing section (t) ₃ -t ₄ ) During which the bipolar energy application is gradually reduced. Bipolar energy application ends at the seal segment (t) ₃ -t ₄ ) At the end and before the start of the cutting/transecting phase.

In addition to the above, monopolar energy application to the tissue is activated during the tissue coagulation phase. In the example shown in FIG. 19, at time t ₂ Here, the activation of unipolar energy begins at the end of the eclosion segment and at the beginning of the tissue warming segment. Like the bipolar energy, the monopolar energy applied to the tissue is gradually increased to a predetermined power level (e.g., 75W) maintained at the remainder of the tissue warming segment and the initial portion of the sealing segment.

Sealing section (t) in the tissue coagulation phase ₃ -t ₄ ) During this time, the monopolar energy power applied to the tissue is gradually increased as the bipolar energy power applied to the tissue is gradually decreased. In the illustrated example, at the end of the tissue coagulation cycle (t) ₄ ) Stop toThe tissue applies bipolar energy. The tissue transection phase begins at t ₄ Is guided by an inflection point in the unipolar power curve 31014, at this time, in the sealed section (t) ₃ -t ₄ ) The previous gradual increase in monopolar energy experienced during this period is followed by a step up to a predetermined maximum threshold power level (e.g., 150W) sufficient to transect the coagulated tissue. The maximum power threshold is maintained for a predetermined period of time that ends when the unipolar power level returns to zero.

Thus, the tissue treatment cycle 31000 is configured to be capable of delivering three different energy modalities to the tissue treatment region over three consecutive time periods. The first energy modality comprising bipolar energy rather than unipolar energy is from t during the emergence segment ₁ To t ₂ Is applied to the tissue treatment area. The second energy modality is a hybrid energy modality comprising a combination of monopolar and bipolar energy, from t during the tissue warming and tissue sealing segments ₂ To t ₄ Is applied to the tissue treatment area. Finally, a third energy modality comprising monopolar energy instead of bipolar energy is selected from t during the cutting segment ₄ To t ₅ Is applied to the tissue. Further, the second energy modality includes a power level that is a sum of power levels of the monopolar energy and the bipolar energy. In at least one example, the power level of the second energy modality includes a highest threshold (e.g., 120W). In various aspects, monopolar and bipolar energy can be delivered to the end effector from two different power generators.

The hybrid power curve 31012 applied during the hybrid energy phase 31004 represents the combination of bipolar and monopolar energy applied to the tissue. In the tissue warming segment (t) ₂ -t ₃ ) Meanwhile, hybrid power curve 31012 is at t ₂ Rises and increases as the monopolar power is activated, while the bipolar power rises during the tissue temperature rise period (t) ₂ ，t ₃ ) During the remaining part of (a) and tissue sealing section (t) ₃ -t ₄ ) Is maintained at a constant or at least substantially constant level. In the sealing section (t) ₃ -t ₄ ) Meanwhile, the hybrid power curve 31012 is maintained at a constant, or at least substantially constant, power by gradually decreasing the bipolar power level as the unipolar power level increasesAnd (7) flattening.

In various aspects, the bipolar and/or unipolar power levels of the tissue treatment cycle 31000 can be adjusted based on one or more measured parameters including tissue impedance, jaw motor speed, jaw motor force, jaw aperture of the end effector, and/or current draw of a motor affecting end effector closure.

According to at least one embodiment, a monopolar electrode for cutting tissue of a patient includes a monopolar cam lobe electrode and a wire connected thereto. The monopolar cam-lobe electrode is initially located at a distal end of an end effector of the electrosurgical instrument. When the clinician wishes to cut patient tissue, the monopolar cam lobe electrode is functional (i.e., via a power generator, as described herein) and pulled by a wire attached thereto. The wire first guides the cam-lobe electrode to rotate up the centerline of the end effector into the tissue gap and then is pulled from the distal end to the proximal end to cut the patient tissue. In other words, if the pivoting cutting blade is at the distal end and then pulled proximally, the cam-lobe electrode acts like a pivoting cutting blade of a surgical instrument. Further, in at least one embodiment, the wire attached to the cam-lobe electrode is offset from the center of rotation of the cam-lobe electrode such that when the wire is pulled proximally, the cam-lobe electrode initially rotates to a vertical position. The cam-lobe electrodes apply force perpendicularly to opposite sides of the end effector jaw from which the cam-lobe electrodes are positioned. In such an arrangement, the cam-lobe electrode may be initially hidden from the tissue gap between the jaws of the end effector until the wire initially pulls on the cam-lobe electrode to rotate the cam-lobe electrode to its vertical position. Because the cam-lobe electrode is initially hidden, the load that the cam-lobe exerts on the other jaw of the end effector is independent of the tissue gap. In other words, the cam-lobe electrode will be substantially upright before distal-to-proximal motion is initiated, or the cam-lobe electrode will be partially upright before distal-to-proximal motion is initiated. The amount that the cam-lobe electrode is rotated toward its vertical position depends on the amount of tissue positioned between the jaws of the end effector and the stiffness of the tissue. For example, stiffer tissue is more resistant to rotation of the cam-lobe electrode to its vertical position than softer tissue before the cam-lobe electrode begins to move from the distal end toward the proximal end.

Fig. 20 shows an electrosurgical instrument 40100 that includes a housing, a shaft 40110 extending from the housing, and an end effector 40120 extending from the shaft 40110. The articulation joint 40130 rotationally links the shaft 40110 and the end effector 40120 to facilitate articulation of the end effector 40120 relative to the shaft 40110. The circuit board 40140 is located in the housing of the instrument 40100. However, other embodiments are contemplated in which circuit board 40140 is positioned in any suitable location. In at least one example, circuit board 40140 is a printed circuit board. Printed circuit board 40140 includes a connector plug 40142 for connecting printed circuit board 40140 to wiring assembly 40150. Wiring assembly 40150 extends from printed circuit board 40140 through shaft 40110 and into end effector 40120. The wiring assembly 40150 is configured to monitor at least one function of the end effector 40120 and relay the monitored information to the printed circuit board 40140. The wiring assembly 40150 can monitor end effector functions, including, for example, compressibility of the jaws of the end effector 40120 and/or thermal cycling of the end effector 40120. In the illustrated example, the wiring assembly 40150 includes a sensor 40122 positioned in the end effector 40120. The sensor 40122 monitors at least one function of the end effector 40120.

In various aspects, the sensor 40122 may include any suitable sensor, such as, for example, a magnetic sensor (such as a hall effect sensor), a strain gauge, a pressure sensor, an inductive sensor (such as an eddy current sensor), a resistive sensor, a capacitive sensor, an optical sensor, and/or any other suitable sensor. In various aspects, circuit board 40140 comprises a control circuit comprising a microcontroller having a processor and a memory unit. The memory unit may store one or more algorithms and/or look-up tables to identify certain parameters of the end effector 40120 and/or tissue grasped by the end effector 40120 based on the measurements provided by the sensor 40122.

In addition to the above, the wiring assembly 40150 can include several flexible, rigid, and/or stretchable portions as part of a flexible circuit to allow the wiring assembly 40150 to flex, bend, and/or stretch across various component boundaries and/or joints of the surgical instrument 40100. For example, as the wiring assembly 40150 passes through a component boundary or joint, the inextensible flexible plastic substrate (i.e., polyimide, peek, transparent conductive polyester film) transitions to a flexible silicone or elastomer substrate and then back to the inextensible flexible substrate on the other side of the joint. The metal conductors within wiring assembly 40150 remain continuous, but are stretchable over component boundaries and/or contacts. This arrangement makes the entire circuit flexible, with the local portions being flexible in at least two planes. Thus, the portion of the wiring assembly 40150 that spans the component boundaries and/or joints allows local relative motion without tearing or losing continuity of the wiring assembly 40150. The wiring assembly 40150 is secured around the local motion region to protect the wiring assembly 40150 from excessive strain and/or deformation.

In addition to the above, in this embodiment, the wiring assembly 40150 comprises a first resilient portion 40152, a proximal rigid portion 40154, a second resilient portion 40156, and a distal rigid portion 40158. The proximal rigid portion 40154 is positioned in the elongate shaft 40110 and the distal rigid portion 40158 is positioned in the end effector 40120. The first resilient portion 40152 is positioned between the printed circuit board 40140 and the proximal rigid portion 40154. The second resilient portion 40156 is positioned between the proximal rigid portion 40154 and the distal rigid portion 40158. Other embodiments are contemplated in which the wiring assembly 40150 includes more or less than two resilient portions. The rigid portions 40154, 40158 can be secured to the shaft 40110 and end effector 40120, respectively, with, for example, an adhesive 40105. However, any suitable attachment means may be used. The elastic portions 40152, 40156 also include resilient portions (i.e., for bending and/or flexing) and stretchable portions (i.e., for stretching). In at least one embodiment, the resilient portion includes a first substrate or layer and the stretchable portion includes a second substrate or layer. The first substrate and the second substrate comprise different materials. However, other embodiments are contemplated in which the first substrate and the second substrate comprise the same material in different structures.

In addition to the above, the wiring assembly 40150 also includes electrical traces or conductors 40160 that span the entire length of the wiring assembly 40150 and are configured to carry electrical energy between the printed circuit board 40140 and the end effector 40120. Referring primarily to fig. 21 and 22, the conductor 40160 includes a stretchable portion 40162 that spans the elastic portions 40152, 40156. The stretchable portion 40162 comprises a serpentine, oscillating, and/or zigzag pattern that allows stretching of the stretchable portion 40162 when the elastic portions 40152, 40156 are extended as shown in figure 22. When the elastic portions 40152, 40156 return to their relaxed and/or natural state, the stretchable portion 40162 returns to its serpentine, oscillating, and/or zigzag pattern as shown in figure 21.

In addition to the above, in at least one embodiment, the conductor 40160 can be used for high current applications, such as RF therapy energy, wherein the conductor 40160 comprises a copper conductor printed into the wiring assembly 40150 in a serpentine, oscillating, and/or zigzag pattern. Other embodiments are contemplated in which the stretchable portion 40162 of the conductor 40160 spanning the elastic portions 40152, 40156 includes conductive couplings that interlock to allow the stretchable portion 40162 to stretch across the joint.

Fig. 23 illustrates an electrosurgical instrument 40200 including a shaft 40210, a translating member 40220, and a flexible circuit and/or wiring harness 40230. The wiring harness 40230 may be similar to the wiring assembly 40150. The translating member 40220 may be, for example, a knife drive rod, articulation cable, and/or a rigid articulation member of the instrument 40200 for incising patient tissue. However, the translating member 40220 may be any translating member described herein. In any case, the translating member 40220 is configured to translate relative to the shaft 40210 and includes a ferrous element 40222 that translates with the translating member 40220. For example, the ferrous elements 40222 may be attached to or housed within the translating member 40220. Harness 40230 is fixed within shaft 40210 and includes a linear induction sensor 40232 configured to detect the linear position of ferrous elements 40222 and, therefore, the linear position of translating member 40220. More specifically, the linear induction sensor 40232 is configured to generate an electric field that is destroyed by the ferrous elements 40222. The linear induction sensor 40232 is integrated into the wiring harness 40230 to provide robust protection for external components and fluids.

In various aspects, the sensor 40232 may be a magnetic sensor (such as a hall effect sensor), a strain gauge, a pressure sensor, an inductive sensor (such as an eddy current sensor), a resistive sensor, a capacitive sensor, an optical sensor, and/or any other suitable sensor. In various aspects, the control circuitry includes a microcontroller having a processor and a memory unit that stores one or more algorithms and/or look-up tables to identify certain parameters of the surgical instrument 40200 and/or tissue being treated by the surgical instrument 40200 based on measurements provided by the sensor 40232.

Fig. 24 and 25 illustrate an electrosurgical instrument 40300 including a shaft 40310, a translating member 40320, and a flexible circuit or wire harness 40330. The translating member 40320 is configured to translate relative to the shaft 40310 to perform an end effector function. The translating member 40320 can be, for example, a knife drive rod, articulation cable, and/or a rigid articulation member of the instrument 40300 for incising patient tissue. However, the translating member may be any translating member such as described herein. In any case, the wire harness 40330 includes a conductor 40331, a main body portion 40332, and a resilient portion 40334 extending from the main body portion 40332. The body portion 40332 is secured to the shaft 40310 and includes a first sensor 40340 configured to measure a function of an end effector of the surgical instrument 40300. The resilient portion 40334 is attached to the translating member 40320 and includes a second sensor 40350. The second sensor 40350 is positioned at an end of the resilient portion 40334, wherein the resilient portion 40334 is attached to the translating member 40320. Thus, the second sensor 40350 translates with the translating member 40320. The second sensor 40350 is configured to measure stress and/or strain within the translating member 40320. However, other embodiments are contemplated in which the second sensor is configured to measure the position, velocity, and/or acceleration of the translating member 40320.

In various aspects, the control circuitry includes a microcontroller having a processor and a memory unit that stores one or more algorithms and/or look-up tables to identify certain parameters of the surgical instrument 40300 and/or tissue treated by the surgical instrument 40300 based on measurements provided by the sensors 40340, 40350.

In addition to the above, the resilient portion 40334 is similar to the resilient portions 40152, 40156 described herein with respect to fig. 20-22. More particularly, the elastic portion 40334 includes a resilient and/or stretchable portion that allows the elastic portion 40334 to bend, flex and/or stretch relative to the body portion 40332 of the wire harness 40330. This arrangement allows the second sensor 40350 to be integrated into the beam 40330 without the detected measurements of the second sensor 40350 being affected by movement of the translation member 40320 relative to the beam 40330.

Figures 26-33 illustrate an electrosurgical instrument 40400 that includes a handle 40410, a shaft 40420 extending from the handle 40410, and a distal head or end effector 40430 extending from the shaft 40420. The handle 40410 includes a trigger 40412 and an electric motor assembly 40411 including a motor 40411a driven by a motor driver/controller 40422b configured to drive the motor 40411a in accordance with each input from the control circuitry 40413 and in response to an actuating motion of the trigger 40412. In various aspects, the control circuitry 40413 includes a microcontroller 40414 having a processor 40415 and a memory unit 40417. A power source 40418 is coupled to the motor controller 40411b for providing power to the motor and to the microcontroller 40414.

The shaft 40420 defines a shaft axis SA and includes an end effector drive member, such as end effector drive member 40419. The end effector drive member 40419 is operably responsive to the electric motor 40411a in the handle 40410 and is configured to perform at least two end effector functions. The end effector 40430 is configured to be selectively locked and unlocked from the shaft 40420 as described herein. More specifically, when the end effector 40430 is locked to the shaft 40420, the end effector 40430 cannot rotate and/or articulate relative to the shaft 40420, and the end effector drive member 40419 is configured to open and close the jaws of the end effector 40430. Further, when the end effector 40430 is unlocked from the shaft 40420, the end effector can rotate and/or articulate relative to the shaft 40420, and when the end effector drive member 40419 is actuated by an electric motor, the end effector drive member 40419 causes the end effector 40430 to rotate about the shaft axis SA.

The instrument 40400 also includes a manual switching or rocker member 40440, an elongate shaft 40450, and a cable 40460. The elongate shaft 40450 is crimped over the cable 40460 such that the elongate shaft 40450 and the cable 40460 move together along the shaft axis SA. The rocker member 40440 includes a slot 40442 defined therein that is configured to receive the elongate shaft 40450. The rocker member 40440 and the elongate shaft 40450 are mounted within the handle 40410 and the portions of the rocker member 40440 that extend laterally beyond each side of the handle 40410 to allow a clinician to manually actuate the rocker member 40440. The rocker member 40440 also includes a pin 40444 that extends into the slot 40442. The pin 40444 extends into a V-shaped groove 40452 defined in the outer diameter of the elongate shaft 40450. The elongate shaft 40450 is biased away from the rocker member 40440 (i.e., distally), such as by a spring.

In use, as the rocker member 40440 is rotated in the clockwise direction CW, the pin 40444 slides within the first side of the V-shaped groove 40452 and retracts the elongate shaft 40450 toward the rocker member 40440 (i.e., proximally). As the rocker member 40440 is rotated in the counterclockwise direction CCW, the pin 40444 slides within a second side of the V-shaped groove 40452 opposite the first side and retracts the elongate shaft 40450 toward the rocker member 40440 (i.e., proximally). Referring to FIG. 31, when the rocker member 40440 is centered, the elongate shaft 40450 is in its distal-most position (i.e., furthest from the rocker member 40440). Referring to fig. 32 and 33, as the rocker member 40440 is rotated in either the clockwise CW or counterclockwise CCW directions, the elongate shaft 40450 is retracted toward (i.e., proximally of) the rocker member 40440.

As described above, the elongate shaft 40450 is crimped over the cable 40460. Thus, as the rocker member 40440 rotates in either the clockwise direction CW or the counterclockwise direction CCW, the cable 40460 is retracted. Lanyard 40460 may be similar to unlock cable 11342 shown in FIG. 54 of U.S. patent application Ser. No. END9234USNP 2/190717-2. More specifically, the cable 40460 unlocks the end effector 40430 when retracted (i.e., when moved proximally) to allow the end effector 40430 to rotate and/or articulate relative to the shaft 40420. Thus, when the rocker member 40440 is rotated in either the clockwise direction CW or the counterclockwise direction CCW, the end effector 40430 is unlocked to allow the end effector 40430 to rotate and/or articulate.

In addition to the above, the rocker member 40440 also includes a downwardly extending post 40446 that is configured to engage a first switch 40447 and a second switch 40448 that are positioned on either side of the downwardly extending post 40446. The first switch 40447 and the second switch 40448 are configured to activate an articulation motor positioned within the handle 40410. More specifically, when the rocker member 40440 is rotated in the clockwise direction CW, the cable 40460 is retracted to unlock the end effector 40430 and the post 40446 engages the first switch 40447, causing the motor 40411a to rotate in a first direction, which causes the articulation drive assembly 40417 to articulate the end effector 40430 to the right, for example. When the rocker member 40440 is rotated in the counterclockwise direction CCW, the cable 40460 is retracted to unlock the end effector 40430. The post 40446 engages the second switch 40448 causing the motor 40411a to rotate in a second direction opposite the first direction, thereby causing the articulation drive assembly 40417 to articulate the end effector 40430 to the left.

In addition to the above, when the rocker member 40440 is centered, as shown in figure 28, neither the first switch 40447 nor the second switch 40448 are activated. The cable 40460 is in its distal-most position corresponding to the end effector 40430 being locked, as described above. In various aspects, any suitable shift or clutch mechanism can be configured to shift the drive member 40419 between operative engagement with the articulation drive assembly 40417 and operative engagement with the closure/firing assembly 40421. The shift mechanism may be actuated by the rocker member 40440 such that the drive member 40419 is operably coupled to the closure/firing drive assembly 40421 when the rocker member 40440 is centered and the drive member is operably coupled to the articulation drive assembly 40417 when the rocker member 40440 is rotated in either the clockwise direction CW or the counterclockwise direction CCW from the centered position.

When the end effector 40430 is locked, rotation of the electric motor in the handle 40410 causes rotation of the end effector drive member 40419 to cause the closure/firing drive assembly 40421 to move the pair of jaws of the end effector 40430 between the open and closed positions. However, other embodiments are contemplated wherein rotation of the end effector drive member 40419 translates the firing member through the end effector 40430 when the end effector 40430 is locked. In any event, when the rocker member 40440 is rotated in either the clockwise CW or counterclockwise CCW direction, the end effector 40430 is unlocked, which allows the end effector 40430 to rotate about the shaft axis SA. More specifically, when the end effector 40430 is unlocked and the end effector drive member 40419 is actuated by the electric motor 40411a in the handle 40410, the end effector 40430 is rotated relative to the shaft 40420 about the shaft axis SA.

In addition to the above, other embodiments are contemplated having a plurality of articulation motors, wherein the articulation motors are operably responsive to a first switch 40447 and a second switch 40448. For example, if a dual articulation joint is employed between the end effector 40430 and the shaft 40420, such an arrangement facilitates articulation of the end effector 40430 about multiple axes. Other embodiments having separate motors dedicated to closing, firing, and/or articulation are also contemplated.

In various aspects, the motor driver 40411b is configured to be capable of operating the electric motor 40411a in a plurality of operating states based on input from the processor 40416. For example, when the end effector drive member 40419 is opening and closing the jaws of the end effector 40430 (i.e., the distal head or end effector 40430 is locked), the electric motor is in the first mode of operation. When the electric motor 40411a is in the first operating mode, the end effector drive member 40419 operates to open and close the jaws of the end effector 40430 at a first speed, at a first rate, with a first amount of torque, and/or with a first amount of acceleration. When the end effector drive member 40419 rotates the end effector 40430 about the shaft axis SA (i.e., the distal head or end effector 40430 is unlocked), the electric motor 40411a is in the second mode of operation. When the electric motor 40411a is in the second mode of operation, the end effector drive member 40419 is operated to rotate the end effector 40430 at a second speed, at a second rate, with a second amount of torque, and/or with a second amount of acceleration.

In at least one embodiment, the first and second modes of operation are different and include different combinations of control parameters to drive the end effector drive member 40419, e.g., at different speeds, torques, and/or accelerations. In at least one embodiment, the second mode of operation (i.e., distal head rotation) includes, for example, a lower maximum torque limit, an acceleration gradient that allows fine adjustment, and/or a lower maximum torque speed than the first mode of operation. In contrast, in the first mode of operation, the end effector drive member 40419 includes, for example, a higher torque limit, does not include or include a limited acceleration gradient, and/or rotates at a faster speed.

In various aspects, the memory 40415 stores program instructions that, when executed by the processor 40416, cause the processor 40416 to select one of the first or second operating modes. The processor 40416 may select various combinations of control parameters, e.g., to drive the end effector drive member 40419 at different speeds, torques, and/or accelerations, from a look-up table, algorithm, and/or formula stored in the memory 40415.

In addition to the above, referring to FIG. 29, a control circuit 40413 controls the speed, torque, and/or acceleration of the articulation motor. The articulation motor is actuated by the first switch 40447 and the second switch 40448 to articulate the end effector 40430 relative to the shaft axis SA, as described above. In at least one embodiment, the first switch 40447 and the second switch 40448 are adaptively controlled. The microcontroller 40414 can be in signal communication with the first switch 40447 and the second switch 40448 to provide proportional speed control of the motor 40411a to articulate the end effector 40430 based on manual movement of the rocker member 40440. More specifically, the distance and/or force to depress the first switch 40447 or the second switch 40448 is directly proportional to the speed, torque, and/or acceleration at which the end effector 40430 is articulated. Alternatively, in some examples, the switches 40447 and 40448 communicate directly with the motor driver 40411 b.

As shown in fig. 29, various embodiments are contemplated wherein the surgical instrument 40400 includes a transmission, a shiftable motor driver, and/or a shifter 40427 to lock together two drive mechanisms, such as, for example, an end effector drive shaft 40419 and an articulation drive assembly 40417 that drives articulation of the end effector 40430, or to lock the end effector drive shaft 40419 and the closure/firing drive assembly 40421. In this arrangement, the surgical instrument 40400 includes a single electric motor 40411a to drive articulation of the end effector 40430, rotate the end effector 40430 about the shaft axis SA, and open and close the jaws of the end effector 40430. More specifically, the shifter 40427 switches a single electric motor between engagement with the articulation drive assembly 40417 and engagement with the closure/firing drive assembly 40421.

According to at least one embodiment, a handle user control for movement of a motor and/or end effector of a surgical instrument is in signal communication with a control system of the surgical instrument. The control system is housed within the handle and couples user-triggered feedback to motor-driven feedback of the end effector to provide proportional, but not direct, control of the end effector. In at least one embodiment, the control system provides indirect open loop control of the end effector with an alternative means for providing clamp level feedback to the user. The surgical instrument includes a haptic feedback and trigger scan association. In addition, the surgical instrument includes a feedback system to the control system for monitoring the alternating compression or pressure in the jaws to compensate for the elimination of the tactile feedback. In this arrangement, the manual user input drives the jaws independent of the stroke of the trigger. In at least one embodiment, the operability of the manual control and handle is improved with a small trigger having a spring-return finger size. Further, in at least one embodiment, modular connection of the power backbone to the surgical instrument is employed when a new disposable shaft is introduced.

Figure 35 illustrates a graph 40500 of a power schematic of a surgical system 40550 (figure 34) including an electrosurgical instrument 40551 and a power source (e.g., power generator) 40552 configured to supply power to the electrosurgical instrument 40551. The electrosurgical instrument 40551 includes an integrated or stand-alone power source that works in conjunction with a separate power generator 40552 to provide power to the motor and other components of the electrosurgical instrument 40551. The integrated power source includes a charge accumulation device, such as a rechargeable, non-removable battery 40553. The battery 40553 is configured to be able to begin recharging once the battery 40553 is attached to the power output of the generator 40552. The integrated power source may begin recharging, for example, during use within a protocol. The integrated power source or rechargeable battery draws a constant level of power from the power output generator 40552 regardless of the power consumed by the motor, controller and/or sensor until the rechargeable battery 40553 charges to a maximum predetermined level. The battery 40553 may be simultaneously discharged to operate the controller or motor of the electrosurgical instrument 40551 and charged via the power output generator 40552. The battery 40553 continues to charge until it reaches a predetermined level between user-requested operations during generator initialization or in a wait state between uses. If the battery 40553 is depleted to a minimum predetermined level, the user is notified that they must wait for a period of time until the battery 40553 is charged above the minimum threshold level before the electrosurgical instrument 40551 can be used again.

In addition to the above, the graph 40500 of figure 35 includes graphs 40502, 40504, 40506, 40508, which include a Y-axis representing various parameters of the surgical system 40550 plotted against time t on the X-axis. The graph 40502 depicts on the Y-axis the power in watts (W) supplied by the generator 40552 to the power source of the electrosurgical instrument (e.g., an internal charge accumulation device such as a rechargeable battery 40553). Graph 40504 depicts on the Y-axis the charge level of battery 40553 as a percentage of the highest charge level threshold. The graph 40506 depicts, on the Y-axis, the power in watts (W) drawn by components of the surgical instrument 40551, such as, for example, the motor 40554, from the battery 40553. Graph 40508 depicts the motor speed limit on the Y-axis as a percentage of the maximum motor speed threshold.

In the illustrated example, the electrosurgical instrument 40551 is at time t ₀ Is connected to a generator 40552. The generator 40552 charges the rechargeable battery 40553 at a constant recharge rate (S1) until the charge level of the battery 40553 reaches at t ₁ The highest threshold of 100% reached. The power source of the generator 40552 is automatically activated when the surgical instrument 40551 is connected to the generator 40552 and automatically deactivated once the charge level reaches a maximum threshold. In various examples, the surgical system 40550 includes control circuitry 40555 having a charge meter 40556 for detecting a charge level of the battery 40553, and a switching mechanism for deactivating a power source to the surgical instrument 40551 when the charge level reaches a maximum threshold. In at least one example, the battery may be charged at a constant rate of 15W. When the battery charge level reaches 100%, the generator will automatically stop charging the battery 40553.

Furthermore, at time t ₂ Here, the motor 40554 is activated to cause the end effector 40557 of the surgical instrument 40551 to perform one or more functions. The motor 40554 draws power from the battery 40553, causing the battery 40553 to operate at a rate S ₂ And (4) discharging. The battery 40553 continues to charge while the motor 40554 is discharged. Thus, the discharge rate S ₂ Derived from the combination of the rate of discharge of the battery 40553 caused by the motor drawing power from the battery and the rate of charge of the battery 40553 caused by the power supplied to the battery 40553 by the generator 40552, these two events occur in parallel or simultaneously until the motor 40554 is deactivated. Once the power draw by the motor 40554 is stopped, the battery 40553 returns to recharging at a constant rate S1.

In the illustrated example, the motor 40553 is activated in the first and second instances 40501, 40503, as shown in the graph 40506, to open and close the jaws of the end effector 40557, for example, to grasp tissue. The clinician may open and close the jaws multiple times to achieve good grasping of the tissue. At the end of the second instance of motor activation 40503, the battery 40553 returns to recharging at a constant rate S1 until at t ₃ The 100% charge level is reached at which point the generator 40552 stops supplying power to the battery 40553. Additionally, for articulating the end effector 40557The third instance of motor activation 40505 causes the battery 40553 to run from time t ₄ To time t ₅ At a rate S ₃ And (4) discharging. The end effector closing/opening and articulation can be driven by the same or different motors drawing power from the battery 40553.

Further, as shown in the graphs 40504, 40506, the fourth, fifth, sixth and seventh instances 40507, 40509, 40511, 40513 of motor activation cause the charge level of the battery 40553 to reach and exceed a first predetermined minimum threshold (e.g., 40%) and a second predetermined minimum threshold (e.g., 20%). The motor driver/controller 40558 of the electrosurgical instrument 40551, which is in signal communication with the generator 40552 and the battery 40553, maintains the motor speed limit at 100% until the battery charge level drops to a first predetermined threshold level. When the charge level of the battery 40553 is at time t ₆ When the motor speed falls to a first predetermined level (e.g., 40%), the motor controller 40558 decreases the motor speed limit (e.g., to 50%) to conserve battery power. Thus, when the battery charge level is 40% and the jaws of the end effector 40557 are actuated, the instrument will first close the jaws of the end effector 40557 at a first reduced speed, which results in the motor activating instance 40509 for time period t _b Longer than time period t of motor activation example 40507 _a . Further, when the charge level is at time t ₇ When the motor speed limit falls to a second predetermined level (e.g., 20%), the motor controller 40558 decreases the motor speed limit to 25% to further conserve battery power. When the battery charge level is 20% and the jaws of the end effector 40557 are actuated, the instrument will clamp the jaws of the end effector 40557 at a second reduced speed that is less than the first reduced speed, which results in the motor activating the time period t of instance 40513 _c Longer than time period t of motor activation example 40509 _b . Thus, the motor controller 40558 causes the motor to perform similar functions at different speeds based on the respective charge levels of the batteries 40553 supplying power to the motor 40554.

In addition, when the charge level of the battery 40553 is at time t ₈ Down to a predetermined minimum level (e.g., 10%), the motor speed limit drops to zero, and the surgical instrument alerts the clinician to wait until the battery 40553 at time t ₉ To charge above a predetermined minimum level (e.g., 40%). When the battery 40553 is recharged from 10% to 40% and the jaw of the end effector 40557 is actuated in the motor activation instance 40515, the surgical instrument 40551 will move the jaw of the end effector 40557 at a first reduced speed for a period of time t that is shorter than the period of time ta _d . At time period t at activation instance 40515 _d Upon completion of the finish, the battery 40553 begins to recharge at a constant rate S ₁ Recharged until it is at t ₁₀ The highest charge level is reached at which point the generator 40552 stops supplying power to the battery 40553.

Figure 34 is a simplified schematic diagram of a surgical system 40550 including control circuitry 40550 having a microcontroller 40560 including a processor 40561 and a memory 40562 storing program instructions. When executed, the program instructions cause the processor 40561 to detect the charge level of the battery 40553. In at least one example, the processor 40561 communicates with a charge meter 40556 configured to be able to measure the charge level of the battery 40553. Further, detecting that the charge level of the battery 40553 is equal to or less than a first minimum charge level threshold (e.g., 40%) when the motor 40554 is operating causes the processor to decrease the maximum speed limit of the motor 40554 to a first maximum threshold. In at least one example, the processor 4056 is in communication with a motor driver 40558 configured to control the speed of the motor 40554. In such an example, the processor 40561 signals the motor driver 40558 to decrease the motor speed limit of the motor 40554 to a first highest threshold. Alternatively, in other examples, the processor 40561 may directly control the maximum motor speed limit.

Further, detecting that the charge level of the battery 40561 is equal to or less than a second minimum charge level threshold (e.g., 20%) when the motor 40554 is running causes the processor to reduce the maximum speed limit of the motor 40554 to a second maximum threshold that is less than the first maximum threshold. Further, detecting that the charge level of the battery 40553 is equal to or less than a third minimum charge level threshold (e.g., 10%) when the motor 40554 is operating causes the processor to reduce the maximum speed limit of the motor 40554 to zero activity to stop the motor 40554. The processor 40561 may prevent a restart of the motor 40554 until the minimum charge level is equal to or greater than a predetermined threshold, such as, for example, a second minimum charge level threshold (e.g., 20%).

In certain examples, the processor 40561 can also employ one or more feedback systems 40563 to alert a clinician. In some cases, the feedback system 40563 may include, for example, one or more visual feedback systems, such as a display screen, a backlight, and/or LEDs. In some cases, the feedback system 40563 may include, for example, one or more audio feedback systems, such as a speaker and/or buzzer. In some cases, the feedback system 40563 may include, for example, one or more haptic feedback systems. In some cases, the feedback system 40563 may include a combination of visual, audio, and/or tactile feedback systems, for example.

In addition to the above, in at least one embodiment, the internal battery is charged by an external charge-accumulating device or by an external battery attached to the surgical instrument between and/or during the course of a surgical procedure. In at least one embodiment, the external battery comprises a disposable battery that is introduced into the sterile field in the form of a sterile package and attached to the surgical instrument, e.g., to supplement and/or replace the internal battery. In at least one embodiment, the external battery is the only operating power source for controlling the mechanical operating system, while the Radio Frequency (RF) power for therapeutic treatment of the tissue is supplied, for example, by a power generator. In this arrangement, the external battery is connected to the surgical instrument when the internal battery is insufficient to power the device. More specifically, the external battery is used in conjunction with the internal battery rather than replacing the internal battery. Further, in at least one embodiment, the external battery comprises a disposable battery that is connected to the internal battery of the surgical instrument to charge the internal battery when the surgical instrument is not performing a surgical procedure. The external battery is then disconnected from the surgical instrument for subsequent use by the clinician when supplemental power is required.

Figure 36 illustrates a surgical system 40600 including a surgical instrument 40610, a monopolar power generator 40620, and a bipolar power generator 40630. In the illustrated embodiment, the monopolar power generator 40620 is electrically coupled directly to the motor 40650 of the surgical instrument 40610 and the bipolar power generator 40630 is electrically coupled directly to the battery 40640. The bipolar power generator 40630 is configured to be able to charge a battery 40640, which in turn supplies power to the motor 40650. The unipolar power generator 40620 is configured to be able to directly supply power to the motor 40650 and charge the battery 40640. More specifically, an additional electrical connection 40660 is supplied between the unipolar power generator 40620 and the battery to allow the unipolar power generator 40620 to supply power to the motor 40650 while also supplying power to the battery 40640 to charge the battery 40640. The monopolar power generator 40620 and the bipolar power generator 40630 are configured to be capable of outputting DC power to the battery 40640 and the motor 40650.

In various aspects, the surgical instrument 40610 includes an end effector 40611. The motor 40650 is operably coupled to the end effector 40611 and can be activated to cause the end effector 40611 to perform a variety of functions, such as, for example, moving at least one of the jaws 40613, 40614 of the end effector 40611 to transition the end effector 40611 between the open and closed configurations as shown in figure 36 to grasp tissue positioned between the jaws. Further, the end effector 40611 extends distally from the shaft 40615 and is articulatable relative to the shaft 40611 about a longitudinal axis extending centrally through the shaft 40615 by an actuation motion generated by the motor 40650.

In addition, the surgical instrument 40610 also includes a power source assembly 40616 that delivers power from the generators 40620 and 40630 to the motor 40650 and/or battery 40640. In at least one example, the power source assembly 40616 separately receives a first power from the generator 40620 and a second power from the generator 40630. Power source assembly 40616 is configured to be capable of delivering a second power to battery 40640 to charge the battery to a maximum predetermined charge level at a constant rate (S1). The power source assembly 40616 is also configured to be capable of delivering a first power to the electric motor 40650 and the battery 40650. In the illustrated example, the motor 40650 is powered by the battery 40640 and the generator 40620 in parallel or simultaneously.

Figure 37 shows a graph 40700 of battery charge percentage and motor torque for a surgical system 40600. Line 40710 represents the battery charge percentage of the battery 40640 when only the bipolar power generator 40630 is used with the surgical instrument 40610. Line 40720 represents the combined battery charge percentage when the monopolar power generator 40620 and the bipolar power generator 40630 are used with the surgical instrument 40610. When both the monopolar power generator 40620 and the bipolar power generator 40630 are used to charge the battery 40640, the battery 40640 is charged more quickly than when only one of the monopolar power generator 40620 and the bipolar power generator 40630 are used to charge the battery 40640. Further, line 40730 represents the battery charge percentage of the battery 40650 when only the bipolar power generator 40630 is used with the surgical instrument 40610. Line 40740 represents the motor torque of the motor 40650 when the monopolar power generator 40620 and the bipolar power generator 40630 are used with the surgical instrument 40610. When both the monopolar power generator 40620 and the bipolar power generator 40630 are used to provide power to the motor 40650, the motor 40650 can generate more torque than when only one of the monopolar power generator 40620 and the bipolar power generator 40630 are used to provide power to the motor 40650.

In addition to the above, other embodiments are contemplated in which the unipolar power generator 40620 is configured to be able to supply power only to the motor 40650, and the bipolar power generator 40630 is configured to be able to charge the battery 40640, which in turn supplies additional power to the motor 40650 (i.e., the unipolar power generator 40620 does not charge the battery 40640). Moreover, other embodiments are contemplated in which both the monopolar power generator 40620 and the bipolar power generator 40630 are used only to charge the battery 40640, which in turn supplies power to, for example, the motor 40650. In this arrangement, both the monopolar power generator 40620 and the bipolar power generator 40630 can be synchronized to consistently charge the battery 40640, which in turn is used to operate the motor 40650. In at least one embodiment, more than one motor may be utilized to drive the end effector 40611 of the surgical instrument 40610. In this arrangement, the unipolar power generator 40620 may supply power to one of the motors, and the bipolar power generator 40630 may supply power to the other of the motors. In addition, both the monopolar power generator 40620 and the bipolar power generator 40630 are used to charge a battery 40640, which in turn can be used to provide power to the motor. However, other embodiments are contemplated in which only one of the unipolar power generator 40620 and the bipolar power generator 40630 is used to charge the battery 40640.

Various aspects of the subject matter described herein are set forth in the following examples.

Example set 1

Example 1-a surgical instrument comprising an end effector. The end effector includes a proximal end, a distal end, a first jaw, and a second jaw. The first jaw includes a first electrode. One of the first and second jaws is movable from an open position to a closed position relative to the other of the first and second jaws to grasp tissue therebetween. The second jaw includes a second electrode and a monopolar electrode disposed centrally down the length of the end effector. The first electrode and the second electrode cooperate to deliver bipolar energy to tissue in a bipolar cycle. The monopolar electrode has a wedge shape. The wedge shape tapers in width along the length of the end effector. The monopolar electrode is electrically isolated from the first electrode and the second electrode. The monopolar electrode is configured to be capable of cutting tissue using monopolar energy during a monopolar cycle.

Example 2-the surgical instrument of example 1, wherein the first jaw and the second jaw are laterally curved.

Example 3-the surgical instrument of examples 1 or 2, wherein the monopolar cycle is performed after the bipolar cycle.

Example 4-the surgical instrument of examples 1, 2, or 3, wherein the monopolar cycle is performed independently of the bipolar cycle.

Example 5-the surgical instrument of examples 1 or 2, wherein the monopolar cycle and the bipolar cycle are activated asynchronously during the tissue treatment cycle.

Example 6-the surgical instrument of examples 1, 2, 3, or 4, wherein during the tissue treatment cycle, the monopolar cycle begins after the bipolar cycle begins and before the bipolar cycle terminates.

Example 7-a surgical instrument comprising an end effector. The end effector includes a proximal end, a distal end, a first jaw, and a second jaw. The first jaw includes a first electrode. One of the first and second jaws is movable from an open position to a closed position relative to the other of the first and second jaws to grasp tissue therebetween. The second jaw includes a second electrode and a monopolar electrode electrically isolated from the first electrode and the second electrode. The first and second electrodes cooperate to deliver bipolar energy to tissue in a bipolar cycle. The monopolar electrode includes a compliant flex circuit substrate centrally disposed down a length of the end effector and a conductive member disposed onto the compliant flex circuit substrate. The monopolar electrode is configured to be capable of cutting tissue using monopolar energy during a monopolar cycle.

Example 8-the surgical instrument of example 7, wherein the first jaw and the second jaw are laterally curved.

Example 9-the surgical instrument of examples 7 or 8, wherein the monopolar cycle is performed after the bipolar cycle.

Example 10-the surgical instrument of examples 7, 8, or 9, wherein the monopolar cycle is performed independently of the bipolar cycle.

Example 11-the surgical instrument of examples 7 or 8, wherein the monopolar cycle and the bipolar cycle are activated asynchronously.

Example 12-the surgical instrument of examples 7, 8, 9, or 10, wherein, during the tissue treatment cycle, the monopolar cycle begins after the bipolar cycle begins and before the bipolar cycle terminates.

Example 13-a surgical instrument comprising an end effector. The end effector includes a proximal end, a distal end, a first jaw, and a second jaw. The first jaw includes a first electrode. One of the first and second jaws is movable from an open position to a closed position relative to the other of the first and second jaws to grasp tissue therebetween. The second jaw includes a second electrode and a monopolar electrode disposed centrally down the length of the end effector. The first and second electrodes cooperate to deliver bipolar energy to tissue in a bipolar cycle. The monopolar electrode includes a conductive wire electrically isolated from the first electrode and the second electrode. The monopolar electrode is configured to be capable of cutting tissue using monopolar energy during a monopolar cycle.

Example 14-the surgical instrument of example 13, wherein the monopolar cycle is performed after the bipolar cycle.

Example 15-the surgical instrument of examples 13 or 14, wherein the monopolar cycle is performed independently of the bipolar cycle.

Example 16-the surgical instrument of examples 13, 14, or 15, wherein the electrically conductive wire comprises a flexible central portion.

Example 17-the surgical instrument of examples 13, 14, 15, or 16, further comprising a compliant member, wherein the conductive wire is electrically isolated from the second jaw by the compliant member.

Example 18-the surgical instrument of example 17, wherein the compliant member comprises a deformable dielectric material.

Example 19-the surgical instrument of examples 17 or 18, wherein the compliant member is compressible.

Example 20-the surgical instrument of examples 17, 18, or 19, wherein the compliant member comprises a first compliant member, wherein the first jaw comprises a second compliant member, and wherein the first and second compliant members electrically isolate the conductive wires from the first and second jaws.

Examples set 2

Example 1-a surgical end effector for use with an electrosurgical instrument. The end effector includes a proximal end, a distal end, a first jaw, and a second jaw. A central plane of the surgical end effector extends through the proximal and distal ends. The first jaw is bisected by the central plane in the longitudinal direction. The first jaw includes a first electrode extending along a portion of the first jaw. The first electrode is positioned on a first side of the central plane. The second jaw is bisected by the central plane in the longitudinal direction. At least one of the first jaw and the second jaw is movable to transition the end effector from an open configuration to a closed configuration to grasp tissue positioned between the first jaw and the second jaw. The second jaw includes a second electrode and a compliant substrate. A second electrode extends along a portion of the second jaw. A second electrode is positioned on a second side of the central plane. The first and second electrodes are configured to cooperate to deliver bipolar energy to tissue. The compliant substrate extends along a length of the second jaw. The compliant substrate includes a first compliant portion located on a first side of the central plane, a second compliant portion located on a second side of the central plane, and a unipolar electrode extending along the central plane. A second electrode is mounted to the second compliant portion. The unipolar electrode is mounted on a compliant substrate. The monopolar electrode is configured to be capable of delivering monopolar energy to the tissue. The compliant substrate is configured to apply a biasing force to the second electrode and the monopolar electrode toward the first jaw in the closed configuration.

Example 2-the surgical end effector of example 1, wherein the first compliant portion is smaller than the second compliant portion.

Example 3-the surgical end effector of examples 1 or 2, wherein the second jaw comprises a dielectric coating.

Example 4-the surgical end effector of example 3, wherein the compliant substrate and the dielectric coating define a flush tissue contacting surface.

Example 5-the surgical end effector of examples 3 or 4, wherein the compliant substrate separates the dielectric coating from the monopolar electrode and the second electrode.

Example 6-the surgical end effector of examples 1, 2, 3, 4, or 5, wherein the compliant substrate comprises a porous structure.

Example 7-the surgical end effector of examples 1, 2, 3, 4, 5, or 6, wherein the compliant substrate comprises a resilient honeycomb structure.

Example 8-the surgical end effector of examples 1, 2, 3, 4, 5, 6, or 7, wherein the first jaw further comprises a first porous frame and a first diamond-like coating at least partially covering the first porous frame, wherein the first electrode is disposed on the first diamond-like coating.

Example 9-the surgical end effector of examples 1, 2, 3, 4, 5, 6, 7, or 8, wherein the second jaw further comprises a second porous frame and a second diamond-like coating at least partially covering the second porous frame, wherein the compliant substrate is disposed on the second diamond-like coating.

Example 10-a surgical instrument comprising a shaft and an end effector extending from the shaft. The end effector includes a proximal end, a distal end, a first jaw, and a second jaw. The central plane of the end effector extends through the proximal and distal ends. The first jaw is bisected by the central plane in the longitudinal direction. The first jaw includes a first electrode extending along a portion of the first jaw. The first electrode is positioned on a first side of the central plane. The second jaw is bisected by the central plane in the longitudinal direction. At least one of the first jaw and the second jaw is movable to transition the end effector from an open configuration to a closed configuration to grasp tissue positioned between the first jaw and the second jaw. The second jaw includes a second electrode and a compressible support. A second electrode extends along a portion of the second jaw. A second electrode is positioned on a second side of the central plane. The first and second electrodes are configured to cooperate to deliver bipolar energy to tissue. The compressible support extends along a length of the second jaw. The compressible support includes a first compressible portion located on a first side of the central plane, a second compressible portion located on a second side of the central plane, and a monopolar electrode extending along the central plane. A second electrode is mounted to the second compressible portion. The monopolar electrode is mounted on the compressible support. The monopolar electrode is configured to be capable of delivering monopolar energy to the tissue. The compressible support is configured to apply a spring bias to the second electrode and the monopolar electrode against the first jaw in the closed configuration.

Example 11-the surgical instrument of example 10, wherein the first compressible portion is smaller than the second compressible portion.

Example 12-the surgical instrument of examples 10 or 11, wherein the second jaw comprises a dielectric coating.

Example 13-the surgical instrument of example 12, wherein the compressible support and the dielectric coating define a flush tissue contacting surface.

Example 14-the surgical instrument of examples 12 or 13, wherein the compressible support separates the dielectric coating from the monopolar electrode and the second electrode.

Example 15-the surgical instrument of examples 10, 11, 12, 13, or 14, wherein the compressible support comprises a porous structure.

Example 16-the surgical instrument of examples 10, 11, 12, 13, 14, or 15, wherein the compressible support comprises a resilient cellular structure.

Example 17-the surgical instrument of examples 10, 11, 12, 13, 14, 15, or 16, wherein the first jaw further comprises a first porous frame and a first diamond-like coating at least partially covering the first porous frame, wherein the first electrode is disposed on the first diamond-like coating.

Example 18-the surgical instrument of examples 10, 11, 12, 13, 14, 15, 16, or 17, wherein the second jaw further comprises a second porous frame and a second diamond-like coating at least partially covering the second porous frame, wherein the compressible support is disposed on the second diamond-like coating.

Example 19-a surgical end effector for use with an electrosurgical instrument. The end effector includes a proximal end, a distal end, a first jaw, and a second jaw. The first jaw extends longitudinally between a proximal end to a distal end. The first jaw includes a first electrode extending longitudinally along a portion of the first jaw. The second jaw extends longitudinally between the proximal end and the distal end. At least one of the first jaw and the second jaw is movable to transition the end effector from an open configuration to a closed configuration to grasp tissue positioned between the first jaw and the second jaw. The second jaw includes a second electrode, a monopolar electrode, and a compliant substrate. A second electrode extends longitudinally along a portion of the second jaw. The second electrode is laterally offset from the first electrode. The first and second electrodes are configured to cooperate to deliver bipolar energy to tissue. The monopolar electrode extends longitudinally along the second electrode. The monopolar electrode is configured to deliver monopolar energy to the tissue. The monopolar electrode and the second electrode are fixedly attached to the compliant substrate in a spaced apart arrangement. The compliant substrate is configured to apply a biasing force to the second electrode and the monopolar electrode toward the first jaw in the closed configuration.

Example 20-the surgical end effector of example 19, wherein at least one of the first jaw and the second jaw comprises a dielectric coating.

Example set 3

Example 1-an electrosurgical instrument comprising a housing, a shaft extending from the housing, an end effector extending from the shaft, an articulation joint rotatably connecting the end effector to the shaft, and a wiring circuit. The housing includes a printed circuit control board. The wiring circuit extends from the printed circuit control board through the shaft and into the end effector. The wiring circuit is configured to monitor the function of the end effector and communicate the monitored function to the printed circuit control board. The wiring circuit includes a proximal rigid portion fixed to the shaft, a distal rigid portion fixed to the end effector, and an intermediate portion extending from the proximal rigid portion to the distal rigid portion. The intermediate portion includes a resilient portion and a stretchable portion.

Embodiment 2-the electrosurgical instrument of embodiment 1, wherein the resilient portion comprises a first substrate and the stretchable portion comprises a second substrate, and wherein the first substrate and the second substrate are different.

Example 3-the electrosurgical instrument of examples 1 or 2, wherein the stretchable portion comprises a conductor in a zig-zag configuration, and wherein the conductor is made of a non-stretchable metallic material.

Embodiment 4-the electrosurgical instrument according to embodiments 1, 2 or 3, wherein the stretchable portion comprises a conductor having an accordion shape, and wherein the conductor is made of a non-stretchable metallic material.

Example 5-the electrosurgical instrument of examples 1, 2, 3, or 4, wherein the resilient portion comprises a laminated portion including a substrate.

Example 6-an electrosurgical instrument comprising a housing, a shaft extending from the housing, an end effector extending from the shaft, an articulation joint rotatably connecting the end effector to the shaft, and a wiring circuit. The housing includes a printed circuit control board. The wiring circuit extends from the printed circuit control board through the shaft and into the end effector. The wiring circuit is configured to monitor the function of the end effector and communicate the monitored function to the printed circuit control board. The wiring circuit includes a rigid portion, a resilient portion capable of transitioning between a relaxed configuration and a non-relaxed configuration, and a wire extending through the resilient portion. The wire includes a stretchable portion. The wire is configured to be capable of being elongated when the resilient portion transitions from the relaxed configuration to the non-relaxed configuration.

Example 7-the electrosurgical instrument of example 6, wherein the stretchable portion comprises a zigzag pattern.

Example 8-the electrosurgical instrument of examples 6 or 7, wherein the stretchable portion comprises an oscillating pattern.

Example 9-the electrosurgical instrument of examples 6, 7, or 8, wherein the stretchable portion has an accordion shape.

Example 10-the electrosurgical instrument of examples 6, 7, 8, or 9, wherein the resilient portion comprises a laminate portion including a substrate.

Example 11-an electrosurgical instrument comprising a housing, a shaft extending from the housing, an end effector extending from the shaft, a translating member configured to translate relative to the shaft to perform an end effector function, and a wire harness. The housing includes a printed circuit control board. A wiring harness extends from the printed circuit control board into the shaft. The wire harness includes a rigid body portion secured to the shaft, a resilient portion extending from the rigid body portion, and a wire extending through the rigid body portion and the resilient portion. One end of the resilient portion is attached to the translating member. An end of the resilient portion attached to the translating member includes a sensor configured to measure a property of the translating member.

Example 12-the electrosurgical instrument of example 11, wherein the property of the translating member comprises a stress within the translating member.

Example 13-the electrosurgical instrument of example 11, wherein the property of the translating member comprises a strain within the translating member.

Example 14-the electrosurgical instrument of example 11, wherein the properties of the translating member include stress and strain within the translating member.

Example 15-the electrosurgical instrument of examples 11, 12, 13, or 14, wherein the property of the translating member comprises one of the group consisting of a position of the translating member, a velocity of the translating member, and an acceleration of the translating member.

Example 16-the electrosurgical instrument of examples 11, 12, 13, 14, or 15, wherein the portion of the wire positioned within the resilient portion of the wire harness comprises a stretchable portion.

Example 17-the electrosurgical instrument of example 16, wherein the stretchable portion comprises a zigzag pattern.

Example 18-the electrosurgical instrument of examples 16 or 17, wherein the stretchable portion comprises an oscillating pattern.

Example 19-the electrosurgical instrument of examples 16, 17, or 18, wherein the stretchable portion has an accordion shape.

Example 20-the electrosurgical instrument of examples 11, 12, 13, 14, 15, 16, 17, 18, or 19, wherein the wire harness extends into the end effector and includes a second sensor configured to measure a function of the end effector.

Example set 4

Example 1-a surgical instrument comprising a motor assembly, a shaft defining a shaft axis, a distal head extending from the shaft, a rotary drive member, and a distal head locking member. The distal head is rotatable about the shaft axis. The motor assembly includes a motor and a motor controller. The motor controller is configured to be capable of operating the motor in a first mode of operation and a second mode of operation. The distal head includes an end effector movable between an open configuration and a closed configuration. The rotary drive member is operably responsive to the motor. A rotary drive member is operably engaged with the distal head. The distal head locking member is manually movable between a first position in which the distal head is unlocked from the shaft and a second position in which the distal head is locked to the shaft. When the distal head locking member is in the first position and the rotary drive member is actuated, the distal head rotates relative to the shaft about the shaft axis. When the distal head lock member is in the second position and the rotary drive member is actuated, the end effector is moved from the open configuration toward the closed configuration.

Example 2-the surgical instrument of example 1, wherein the motor assembly is configured to operate in a first mode of operation when the distal head locking member is in the first position, and wherein the motor is configured to operate in a second mode of operation when the distal head locking member is in the second position.

Example 3-the surgical instrument of examples 1 or 2, wherein the motor is configured to rotate the rotary drive member at a first speed when the motor is in a first mode of operation, wherein the motor is configured to rotate the rotary drive member at a second speed when the motor is in a second mode of operation, and wherein the first speed and the second speed are different.

Example 4-the surgical instrument of examples 1, 2, or 3, wherein the motor is configured to generate a first amount of torque when the motor is in the first operating mode, wherein the motor is configured to generate a second amount of torque when the motor is in the second operating mode, and wherein the first amount of torque and the second amount of torque are different.

Example 5-the surgical instrument of examples 1, 2, 3, or 4, wherein the rotary drive member accelerates at a first rate when the motor is in the first mode of operation, wherein the rotary drive member accelerates at a second rate when the motor is in the second mode of operation, and wherein the first rate and the second rate are different.

Example 6-the surgical instrument of examples 1, 2, 3, 4, or 5, further comprising a pull cable operably engaged with the distal head locking member, wherein the pull cable is operably engaged with the distal head to transition the distal head between a first configuration in which the distal head is unlocked from the shaft and a second configuration in which the distal head is locked to the shaft.

Example 7-a surgical instrument comprising a motor assembly, a shaft defining a shaft axis, an end effector extending from the shaft, a rotary drive member, and a mode selector member. The motor assembly includes a motor and a motor controller. The motor controller is configured to be capable of operating the motor in a first mode of operation and a second mode of operation. The end effector is configured to perform a first end effector function and a second end effector function different from the first end effector function. The rotary drive member is operably responsive to the motor. A rotary drive member is operably engaged with the end effector and is configured to selectively perform a first end effector function and a second end effector function. The mode selector member is operably engaged with the end effector and the rotary drive member. The mode selector member is manually movable between a first position in which the end effector performs a first end effector function when the rotary drive member is actuated by the motor, and a second position in which the end effector performs a second end effector function when the rotary drive member is actuated by the motor. The motor is configured to be operable in a first mode of operation when the mode selector member is in the first position. The motor is configured to be operable in a second mode of operation when the mode selector member is in the second position.

Example 8-the surgical instrument of example 7, wherein the motor is configured to rotate the rotary drive member at a first speed when the motor is in a first mode of operation, wherein the motor is configured to rotate the rotary drive member at a second speed when the motor is in a second mode of operation, and wherein the first speed and the second speed are different.

Example 9-the surgical instrument of examples 7 or 8, wherein the motor is configured to generate a first amount of torque when the motor is in the first operating mode, wherein the motor is configured to generate a second amount of torque when the motor is in the second operating mode, and wherein the first amount of torque and the second amount of torque are different.

Example 10-the surgical instrument of examples 7, 8, or 9, wherein the rotary drive member is accelerated at a first rate when the motor is in the first mode of operation, wherein the rotary drive member is accelerated at a second rate when the motor is in the second mode of operation, and wherein the first rate and the second rate are different.

Example 11-a surgical instrument comprising a motor, a shaft defining a shaft axis, an end effector extending from the shaft, a rotary drive member operably responsive to the motor, a locking member operably engaged with the rotary drive member, and a switching member operably engaged with the locking member. A rotary drive member is operably engaged with the end effector and is configured to selectively perform a first end effector function and a second end effector function different from the first end effector function. The locking member is movable between a first position in which the end effector is locked to the shaft and a second position in which the end effector is unlocked from the shaft. The switching member is rotatable about the shaft axis to move the locking member between the first position and the second position. The rotary drive member is configured to perform a first end effector function when the locking member is in the first position. The rotary drive member is configured to perform a second end effector function when the locking member is in the second position.

Example 12-the surgical instrument of example 11, wherein the first end effector function comprises rotation of the end effector about an axis and wherein the second end effector function comprises actuating a pair of jaws of the end effector.

Example 13-the surgical instrument of example 11, wherein the first end effector function comprises translating a firing member through the end effector, and wherein the second end effector function comprises actuating a pair of jaws of the end effector.

Example 14-the surgical instrument of example 11, further comprising an articulation joint, wherein the second end effector function comprises articulation of the end effector relative to the shaft about an articulation axis.

Example 15-the surgical instrument of examples 11, 12, 13, or 14, further comprising a motor controller configured to operate the motor in a first mode of operation and a second mode of operation different from the first mode of operation.

Example 16-the surgical instrument of example 15, wherein the motor controller is configured to operate the motor in a first operating mode when the locking member is in the first position and to operate the motor in a second operating mode when the locking member is in the second position.

Example 17-the surgical instrument of example 16, wherein the motor is configured to rotate the rotary drive member at a first speed when the motor is in a first mode of operation, wherein the motor is configured to rotate the rotary drive member at a second speed when the motor is in a second mode of operation, and wherein the first speed and the second speed are different.

Example 18-the surgical instrument of examples 16 or 17, wherein the motor is configured to generate a first amount of torque when the motor is in a first operating mode, wherein the motor is configured to generate a second amount of torque when the motor is in a second operating mode, and wherein the first amount of torque and the second amount of torque are different.

Example 19-the surgical instrument of examples 16, 17, or 18, wherein the rotary drive member is accelerated at a first rate when the motor is in the first mode of operation, wherein the rotary drive member is accelerated at a second rate when the motor is in the second mode of operation, and wherein the first rate and the second rate are different.

Example 20-the surgical instrument of examples 11, 12, 13, 14, 15, 16, 17, 18, or 19, further comprising a pull cable operably engaged with the locking member and the end effector, wherein the pull cable is configured to transition the end effector between a first configuration in which the end effector is unlocked from the shaft and a second configuration in which the end effector is locked to the shaft.

Example set 5

Example 1-a surgical system comprising a generator and a surgical instrument configured to receive power from the generator. The surgical instrument includes a housing, a shaft extending from the housing, an end effector extending from the shaft, and an internal charge accumulation device in electrical communication with the generator. The housing includes an electric motor. The shaft defines a longitudinal shaft axis. The end effector is operably responsive to actuation from the electric motor. The end effector is transitionable between an open configuration and a closed configuration. The end effector is rotatable relative to the longitudinal shaft axis about an articulation axis that is transverse to the longitudinal shaft axis. The generator cannot directly supply power to the electric motor sufficient to cause the electric motor to perform an actuation. The internal charge accumulation device is configured to be able to supply power to the electric motor. The internal charge-accumulating means is chargeable to the threshold by the generator at a charge rate dependent on a charge level of the internal charge-accumulating means. The charge rate is independent of the charge consumption of the surgical instrument.

Embodiment 2-the surgical system of embodiment 1, wherein the generator is configured to charge the internal charge-accumulation device during charge depletion.

Embodiment 3-the surgical system of embodiments 1 or 2, wherein the generator supplies power to the internal charge-accumulation device at a constant rate while the electric motor draws power from the internal charge-accumulation device when the charge level of the internal charge-accumulation device is below a threshold.

Example 4-the surgical system of examples 1, 2, or 3, wherein the speed of the electric motor is allowed to reach a maximum speed when the charge level of the internal charge-accumulating device is above a predetermined minimum level.

Example 5-the surgical system of example 4, wherein the speed of the electric motor is limited to a reduced speed when the charge level of the internal charge-accumulating device is below a predetermined minimum level.

Example 6-the surgical instrument of examples 1, 2, 3, 4, or 5, wherein the end effector comprises a first jaw and a second jaw, the first jaw comprising an electrode, and wherein the generator is configured to supply a first power to the surgical instrument to cause the electrode to cauterize tissue captured between the first jaw and the second jaw while supplying a second power to the surgical instrument to charge the internal charge accumulation device.

Example 7-the surgical instrument of examples 1, 2, 3, 4, 5, or 6, wherein the internal charge accumulation device comprises a rechargeable battery.

Example 8-the surgical instrument of example 7, wherein the rechargeable battery is integrated with the housing.

Example 9-a surgical system comprising a power source and a surgical instrument configured to receive power from the power source. The surgical instrument includes a housing, a shaft extending from the housing, an end effector extending from the shaft, and an internal charge accumulation device. The housing includes an electric motor. The end effector is operably coupled to the electric motor. The electric motor is configured to drive the end effector to perform an end effector function. The internal charge accumulation device is in electrical communication with a power source. The internal charge accumulation device is configured to be able to supply power to the electric motor. The internal charge-accumulation device is chargeable to the threshold by the power source at a charge rate that depends on a charge level of the internal charge-accumulation device. The internal charge accumulation device is chargeable by the power source while the electric motor drives the end effector to perform an end effector function.

Example 10-the surgical system of example 9, further comprising a control circuit configured to detect a charge level of the internal charge accumulation device, wherein detecting the charge level decreasing to or below a first minimum charge level causes the control circuit to decrease the maximum speed limit of the electric motor to a first minimum speed limit threshold.

Example 11-the surgical system of example 10, wherein detection of the charge level decreasing to or below a second minimum charge level that is less than the first minimum charge level causes the control circuit to decrease the maximum speed limit of the electric motor to a second minimum speed limit threshold that is less than the first minimum speed limit threshold.

Example 12-the surgical system of example 11, wherein detection of the decrease in the charge level to or below a third minimum charge level that is less than the second minimum charge level causes the control circuit to stop the electric motor.

Example 13-the surgical system of example 12, wherein the control circuit is configured to prevent the electric motor from being reactivated until the charge level of the internal charge accumulation device is at or above a third minimum charge level.

Example 14-the surgical system of examples 9, 10, 11, 12, or 13, wherein the power source supplies power to the internal charge-accumulation device at a constant rate while the electric motor draws power from the internal charge-accumulation device when a charge level of the internal charge-accumulation device is below a threshold.

Example 15-the surgical instrument of examples 9, 10, 11, 12, 13, or 14, wherein the end effector comprises a first jaw and a second jaw, the first jaw comprising an electrode, and wherein the power source is configured to supply a first power to the surgical instrument to cause the electrode to cauterize tissue captured between the first jaw and the second jaw while supplying a second power to the surgical instrument to charge the internal charge accumulation device.

Example 16-the surgical instrument of examples 9, 10, 11, 12, 13, 14, or 15, wherein the internal charge-accumulating device comprises a rechargeable battery.

Example 17-the surgical instrument of examples 9, 10, 11, 12, 13, 14, 15, or 16, wherein the power source is a disposable battery.

Example 18-a surgical system comprising a housing, a shaft extending from the housing, an end effector extending from the shaft, and a power source. The housing includes an electric motor and an internal charge accumulation device connected to the electric motor. The electric motor is configured to cause the end effector to perform an end effector function. The power source assembly can be connected to two separate power sources. The power source assembly is configured to be capable of receiving first and second powers, respectively, from a power source. The power source assembly is configured to be capable of delivering a second power to the internal charge accumulation device. The power source assembly is configured to deliver a first power to the electric motor and the internal charge accumulation device. The power source assembly is configured to be capable of simultaneously providing power to the electric motor from the internal charge accumulation device and the first power.

Example 19-the surgical instrument of example 18, wherein the internal charge-accumulation device and the first power are configured to cause the electric motor to generate a first motor torque that is greater than a second motor torque caused by either of the internal charge-accumulation device and the first power alone.

Example 20-the surgical instrument of examples 18 or 19, wherein the internal charge accumulation device comprises a rechargeable battery.

While several forms have been illustrated and described, it is not the intention of the applicants to restrict or limit the scope of the appended claims to such detail. Numerous modifications, variations, changes, substitutions, combinations, and equivalents of these forms can be made without departing from the scope of the present disclosure, and will occur to those skilled in the art. Further, the structure of each element associated with the described forms may alternatively be described as a means for providing the function performed by the element. In addition, where materials for certain components are disclosed, other materials may also be used. It should be understood, therefore, that the foregoing detailed description and the appended claims are intended to cover all such modifications, combinations and permutations as fall within the scope of the disclosed forms of the invention. The appended claims are intended to cover all such modifications, variations, changes, substitutions, modifications, and equivalents.

The foregoing detailed description has set forth various forms of the devices and/or methods via the use of block diagrams, flowcharts, and/or examples. Insofar as such block diagrams, flowcharts, and/or examples contain one or more functions and/or operations, it will be understood by those within the art that each function and/or operation within such block diagrams, flowcharts, or examples can be implemented, individually and/or collectively, by a wide range of hardware, software, firmware, or virtually any combination thereof. Those skilled in the art will recognize that some aspects of the forms disclosed herein, in whole or in part, can be equivalently implemented in integrated circuits, as one or more computer programs running on one or more computers (e.g., as one or more programs running on one or more computer systems), as one or more programs running on one or more processors (e.g., as one or more programs running on one or more microprocessors), as firmware, or as virtually any combination thereof, and that designing the circuitry and/or writing the code for the software and/or hardware would be well within the skill of one of skill in the art in light of this disclosure. In addition, those skilled in the art will appreciate that the mechanisms of the subject matter described herein are capable of being distributed as one or more program products in a variety of forms, and that an illustrative form of the subject matter described herein applies regardless of the particular type of signal bearing medium used to actually carry out the distribution.

Instructions for programming logic to perform the various disclosed aspects may be stored within a memory in a system, such as a Dynamic Random Access Memory (DRAM), cache, flash memory, or other memory. Further, the instructions may be distributed via a network or by other computer readable media. Thus, a machine-readable medium may include any mechanism for storing or transmitting information in a form readable by a machine (e.g., a computer), but is not limited to, floppy diskettes, optical disks, compact disc read-only memories (CD-ROMs), and magneto-optical disks, read-only memories (ROMs), Random Access Memories (RAMs), erasable programmable read-only memories (EPROMs), electrically erasable programmable read-only memories (EEPROMs), magnetic or optical cards, flash memory, or a tangible, machine-readable storage device used in transmitting information over the internet via electrical, optical, acoustical or other forms of propagated signals (e.g., carrier waves, infrared signals, digital signals, etc.). Thus, a non-transitory computer-readable medium includes any type of tangible machine-readable medium suitable for storing or transmitting electronic instructions or information in a form readable by a machine (e.g., a computer).

As used in any aspect herein, the term "control circuitry" can refer to, for example, hardwired circuitry, programmable circuitry (e.g., a computer processor that includes one or more separate instruction processing cores, processing units, processors, microcontrollers, microcontroller units, controllers, Digital Signal Processors (DSPs), Programmable Logic Devices (PLDs), Programmable Logic Arrays (PLAs), Field Programmable Gate Arrays (FPGAs)), state machine circuitry, firmware that stores instructions executed by programmable circuitry, and any combination thereof. The control circuitry may be implemented collectively or individually as circuitry that forms part of a larger system, e.g., an Integrated Circuit (IC), an Application Specific Integrated Circuit (ASIC), a system on a chip (SoC), a desktop computer, a laptop computer, a tablet computer, a server, a smartphone, etc. Thus, as used herein, "control circuitry" includes, but is not limited to, electronic circuitry having at least one discrete circuit, electronic circuitry having at least one integrated circuit, electronic circuitry having at least one application specific integrated circuit, electronic circuitry forming a general purpose computing device configured by a computer program (e.g., a general purpose computer configured by a computer program that implements, at least in part, the methods and/or apparatus described herein, or a microprocessor configured by a computer program that implements, at least in part, the methods and/or apparatus described herein), electronic circuitry forming a memory device (e.g., forming a random access memory), and/or electronic circuitry forming a communication device (e.g., a modem, a communication switch, or an optoelectronic device). Those skilled in the art will recognize that the subject matter described herein may be implemented in an analog or digital fashion, or some combination thereof.

As used in any aspect herein, the term "logic" may refer to an application, software, firmware, and/or circuitry configured to be capable of performing any of the foregoing operations. The software may be embodied as a software package, code, instructions, instruction sets, and/or data recorded on a non-transitory computer-readable storage medium. Firmware may be embodied as code, instructions or instruction sets and/or data that are hard-coded (e.g., non-volatile) in a memory device.

As used in any aspect herein, the terms "component," "system," "module," and the like can refer to a computer-related entity, either hardware, a combination of hardware and software, or software in execution.

An "algorithm," as used in any aspect herein, is a self-consistent sequence of steps leading to a desired result, wherein "step" refers to the manipulation of physical quantities and/or logical states, which may (but are not necessarily) take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. And are used to refer to these signals as bits, values, elements, symbols, characters, terms, numbers, or the like. These and similar terms may be associated with the appropriate physical quantities and are merely convenient labels applied to these quantities and/or conditions.

The network may comprise a packet switched network. The communication devices may be capable of communicating with each other using the selected packet switched network communication protocol. One exemplary communication protocol may include an ethernet communication protocol that may be capable of allowing communication using the transmission control protocol/internet protocol (TCP/IP). The ethernet protocol may conform to or be compatible with the ethernet Standard entitled "IEEE 802.3 Standard" and/or higher versions of the Standard, promulgated by the Institute of Electrical and Electronics Engineers (IEEE) at 12 months 2008. Alternatively or additionally, the communication devices may be capable of communicating with each other using an x.25 communication protocol. The x.25 communication protocol may conform to or be compatible with standards promulgated by the international telecommunication union, telecommunication standardization sector (ITU-T). Alternatively or additionally, the communication devices may be capable of communicating with each other using a frame relay communication protocol. The frame relay communication protocol may conform to or be compatible with standards promulgated by the international telegraph telephone consultancy (CCITT) and/or the American National Standards Institute (ANSI). Alternatively or additionally, the transceivers may be capable of communicating with each other using an Asynchronous Transfer Mode (ATM) communication protocol. The ATM communications protocol may conform to or be compatible with the ATM standard entitled "ATM-MPLS Network Interworking 2.0" promulgated by the ATM forum in 8 months 2001 and/or higher versions of that standard. Of course, different and/or later-developed connection-oriented network communication protocols are also contemplated herein.

Unless specifically stated otherwise as apparent from the above discussion, it is appreciated that throughout the above disclosure, discussions utilizing terms such as "processing," "computing," "calculating," "determining," "displaying" or the like, refer to the action and processes of a computer system, or similar electronic computing device, that manipulates and transforms data represented as physical (electronic) quantities within the computer system's registers and memories into other data similarly represented as physical quantities within the computer system memories or registers or other such information storage, transmission or display devices.

One or more components may be referred to herein as "configured to be able," "configurable to be able," "operable/operable," "adapted/adaptable," "capable," "conformable/conformable," or the like. Those skilled in the art will recognize that "configured to be able to" may generally encompass components in an active state and/or components in an inactive state and/or components in a standby state unless the context indicates otherwise.

The terms "proximal" and "distal" are used herein with respect to a clinician manipulating a handle portion of a surgical instrument. The term "proximal" refers to the portion closest to the clinician and the term "distal" refers to the portion located away from the clinician. It will be further appreciated that for simplicity and clarity, spatial terms such as "vertical," "horizontal," "up," and "down" may be used herein with respect to the drawings. However, surgical instruments are used in many orientations and positions, and these terms are not intended to be limiting and/or absolute.

Those skilled in the art will recognize that, in general, terms used herein, and especially in the appended claims (e.g., bodies of the appended claims) are generally intended as "open" terms (e.g., the term "including" should be interpreted as "including but not limited to," the term "having" should be interpreted as "having at least," the term "includes" should be interpreted as "includes but is not limited to," etc.). It will be further understood by those within the art that if a specific number of an introduced claim recitation is intended, such an intent will be explicitly recited in the claim, and in the absence of such recitation no such intent is present. For example, as an aid to understanding, the following appended claims may contain usage of the introductory phrases "at least one" and "one or more" to introduce claims. However, the use of such phrases should not be construed to imply that the introduction of a claim recitation by the indefinite articles "a" or "an" limits any particular claim containing such introduced claim recitation to claims containing only one such recitation, even when the same claim includes the introductory phrases "one or more" or "at least one" and indefinite articles such as "a" or "an" (e.g., "a" and/or "an" should typically be interpreted to mean "at least one" or "one or more"); this also applies to the use of definite articles used to introduce claim recitations.

In addition, even if a specific number of an introduced claim recitation is explicitly recited, those skilled in the art will recognize that such recitation should typically be interpreted to mean at least the recited number (e.g., the bare recitation of "two recitations," without other modifiers, typically means at least two recitations, or two or more recitations). Moreover, in those instances where a convention analogous to "at least one of A, B and C, etc." is used, in general such a construction is intended in the sense one having skill in the art would understand the convention (e.g., "a system having at least one of A, B and C" would include but not be limited to systems having a alone, B alone, C, A and B together alone, a and C together, B and C together, and/or A, B and C together, etc.). In those instances where a convention analogous to "A, B or at least one of C, etc." is used, in general such construction is intended to have a meaning that one of skill in the art would understand the convention (e.g., "a system having at least one of A, B or C" would include but not be limited to systems having a alone, B alone, C, A and B together alone, a and C together, B and C together, and/or A, B and C together, etc.). It will also be understood by those within the art that, in general, unless the context indicates otherwise, whether a disjunctive word and/or phrase presenting two or more alternative terms in a particular embodiment, claim, or drawing should be understood to encompass the possibility of including one of the terms, either of the terms, or both terms. For example, the phrase "a or B" will generally be understood to include the possibility of "a" or "B" or "a and B".

Those skilled in the art will appreciate from the appended claims that the operations recited therein may generally be performed in any order. Additionally, while the various operational flow diagrams are listed in one or more sequences, it should be understood that the various operations may be performed in other sequences than the illustrated sequences, or may be performed concurrently. Examples of such alternative orderings may include overlapping, interleaved, interrupted, reordered, incremental, preliminary, complementary, simultaneous, reverse, or other altered orderings, unless context dictates otherwise. Furthermore, unless the context dictates otherwise, terms like "responsive," "related," or other past adjectives are generally not intended to exclude such variations.

It is worthy to note that any reference to "an aspect," "an example" means that a particular feature, structure, or characteristic described in connection with the aspect is included in at least one aspect. Thus, the appearances of the phrases "in one aspect," "in an example" in various places throughout this specification are not necessarily all referring to the same aspect. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more aspects.

In this specification, unless otherwise indicated, the term "about" or "approximately" as used in this disclosure refers to an acceptable error for a particular value as determined by one of ordinary skill in the art, which error depends in part on the manner in which the value is measured or determined. In certain embodiments, the term "about" or "approximately" means within 1, 2, 3, or 4 standard deviations. In certain embodiments, the term "about" or "approximately" means within 50%, 20%, 15%, 10%, 9%, 8%, 7%, 6%, 5%, 4%, 3%, 2%, 1%, 0.5%, or 0.05% of a given value or range.

In the present specification, unless otherwise indicated, all numerical parameters should be understood as being referred to or modified in all instances by the term "about" where the numerical parameter is characterized by the inherent variability of the underlying measurement technique used to determine the numerical value of the parameter. At the very least, and not as an attempt to limit the application of the doctrine of equivalents to the scope of the claims, each numerical parameter described herein should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

Any numerical range recited herein includes all sub-ranges subsumed within the recited range. For example, a range of "1 to 10" includes all sub-ranges between the recited minimum value of 1 and the recited maximum value of 10 (including 1 and 10), that is, having a minimum value equal to or greater than 1 and a maximum value of equal to or less than 10. In addition, all ranges set forth herein include the endpoints of the listed ranges. For example, a range of "1 to 10" includes the endpoints 1 and 10. Any upper limit recited in this specification is intended to include all smaller limits encompassed therein, and any lower limit recited in this specification is intended to include all larger limits encompassed therein. Accordingly, applicants reserve the right to modify this specification (including the claims) to specifically list any sub-ranges encompassed within the specifically listed range. This specification inherently describes all such ranges.

Any patent applications, patents, non-patent publications or other published materials mentioned in this specification and/or listed in any application data sheet are herein incorporated by reference, to the extent that the incorporated materials are not inconsistent herewith. Thus, and to the extent necessary, the disclosure as explicitly set forth herein supersedes any conflicting material incorporated herein by reference. Any material, or portion thereof, that is said to be incorporated by reference herein, but which conflicts with existing definitions, statements, or other disclosure material set forth herein will only be incorporated to the extent that no conflict arises between that incorporated material and the existing disclosure material.

In summary, a number of benefits have been described that result from employing the concepts described herein. The foregoing detailed description of one or more forms has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed. Modifications or variations are possible in light of the above teachings. The form or forms selected and described are to be illustrative of the principles and practical applications to thereby enable one of ordinary skill in the art to utilize the various forms and modifications as are suited to the particular use contemplated. The claims as filed herewith are intended to define the full scope.

Claims (20)

1. An electrosurgical instrument, comprising:

a housing including a printed circuit control board;

a shaft extending from the housing;

an end effector extending from the shaft;

an articulation joint rotatably connecting the end effector to the shaft; and

a wiring circuit extending from the printed circuit control board, through the shaft, and into the end effector, wherein the wiring circuit is configured to monitor a function of the end effector and communicate the monitored function to the printed circuit control board, and wherein the wiring circuit comprises:

a proximal rigid portion fixed to the shaft;

a distal rigid portion secured to the end effector, an

A middle portion extending from the proximal rigid portion to the distal rigid portion, wherein the middle portion comprises:

a resilient portion; and

a stretchable portion.

2. The electrosurgical instrument of claim 1, wherein the resilient portion comprises a first substrate and the stretchable portion comprises a second substrate, wherein the first and second substrates are different.

3. An electrosurgical instrument according to claim 1, wherein the stretchable portion comprises a conductor in a zig-zag configuration, and wherein the conductor is made of a non-stretchable metallic material.

4. An electrosurgical instrument according to claim 1, wherein the stretchable portion comprises a conductor having an accordion shape, wherein the conductor is made of a non-stretchable metallic material.

5. An electrosurgical instrument according to claim 1, wherein the resilient portion comprises a laminated portion comprising a substrate.

6. An electrosurgical instrument, comprising:

a housing including a printed circuit control board;

a shaft extending from the housing;

an end effector extending from the shaft;

an articulation joint rotatably connecting the end effector to the shaft; and

a wiring circuit extending from the printed circuit control board through the shaft and into the end effector, wherein the wiring circuit is configured to monitor a function of the end effector and communicate the monitored function to the printed circuit control board, and wherein the wiring circuit comprises:

a rigid portion;

a resilient portion capable of transitioning between a relaxed configuration and a non-relaxed configuration; and

a wire extending through the resilient portion, wherein the wire includes a stretchable portion, and wherein the wire is configured to be stretchable when the resilient portion transitions from the relaxed configuration to the non-relaxed configuration.

7. An electrosurgical instrument according to claim 6, wherein the stretchable portion comprises a zig-zag pattern.

8. An electrosurgical instrument according to claim 6, wherein the stretchable portion comprises an oscillating pattern.

9. An electrosurgical instrument according to claim 6, wherein the stretchable portion has an accordion shape.

10. An electrosurgical instrument according to claim 6, wherein the resilient portion comprises a laminated portion comprising a substrate.

11. An electrosurgical instrument, comprising:

a housing including a printed circuit control board;

a shaft extending from the housing;

an end effector extending from the shaft;

a translating member configured to translate relative to the shaft to perform an end effector function; and

a wire harness extending from the printed circuit control board into the shaft, wherein the wire harness comprises:

a rigid body portion secured to the shaft;

a resilient portion extending from the rigid body portion, wherein an end of the resilient portion is attached to the translating member, wherein the end of the resilient portion includes a sensor, and wherein the sensor is configured to be capable of measuring a property of the translating member; and

a wire extending through the rigid body portion and the resilient portion.

12. The electrosurgical instrument of claim 11, wherein the property of the translating member comprises stress within the translating member.

13. The electrosurgical instrument of claim 11, wherein the property of the translating member comprises strain within the translating member.

14. The electrosurgical instrument of claim 11, wherein the properties of the translating member comprise stress and strain within the translating member.

15. The electrosurgical instrument of claim 11, wherein the property of the translating member comprises one of the group consisting of a position of the translating member, a velocity of the translating member, and an acceleration of the translating member.

16. The electrosurgical instrument of claim 11, wherein the portion of the wire positioned within the resilient portion of the wire harness comprises a stretchable portion.

17. An electrosurgical instrument according to claim 16, wherein the stretchable portion comprises a zig-zag pattern.

18. The electrosurgical instrument of claim 16, wherein the stretchable portion comprises an oscillating pattern.

19. An electrosurgical instrument according to claim 16, wherein the stretchable portion has an accordion shape.

20. The electrosurgical instrument of claim 11, wherein the wire harness extends into the end effector and comprises a second sensor configured to measure end effector function.

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