EP4701553A1 - Surgical end effector assemblies and surgical instruments for energy-based tissue cutting - Google Patents

Abstract

A surgical instrument includes a housing, a shaft assembly, and an end effector assembly. The end effector assembly includes first and second jaw members, at least one of which is movable between spaced apart and approximated positions for grasping tissue between tissue contacting surfaces of the jaw members. The second jaw member includes a jaw housing tapering in height in a distal direction from a first height at a first position to a second height at a second position. The second jaw member further includes a cutting electrode engaged within the jaw housing and extending towards the first jaw member. The cutting electrode tapers in height in a distal direction from a third height at the first position to a fourth height at the second position. The third height is less than the first height but greater than the second height and the fourth height is less than the second height.

Description

SURGICAL END EFFECTOR ASSEMBLIES AND SURGICAL INSTRUMENTS FOR ENERGY-BASED TISSUE CUTTING

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Patent Application Serial No. 63/462,015, filed April 26, 2023, the entire content of which is incorporated herein by reference.

FIELD

[0002] This disclosure relates to surgical instruments and, more specifically, to surgical end effector assemblies and surgical instruments for energy-based tissue cutting such as, for example, for use in surgical robotic systems.

BACKGROUND

[0003] Surgical robotic systems are increasingly utilized in various different surgical procedures. Some surgical robotic systems include a console supporting a robotic arm. One or more different surgical instruments may be configured for use with the surgical robotic system and selectively mountable to the robotic arm. The robotic arm provides one or more inputs to the mounted surgical instrument to enable operation of the mounted surgical instrument.

[0004] A surgical forceps, one type of instrument capable of being utilized with a robotic surgical system, relies on mechanical action between its jaw members to grasp, clamp, and constrict tissue. Electrosurgical forceps utilize both controlled mechanical clamping action and energy to heat tissue to seal (or otherwise treat) tissue. Typically, once tissue is sealed, the tissue is severed using a cutting element. Accordingly, many electrosurgical forceps are designed to incorporate a mechanical cutting element to effectively sever sealed tissue (and/or to cut tissue independently of tissue sealing). Alternatively, surgical forceps may incorporate an energy-based, e.g., thermal, electrical, ultrasonic, etc., cutting mechanism to cut tissue, whether previously sealed or unsealed.

SUMMARY

[0005] As used herein, the term “distal” refers to the portion that is being described which is farther from an operator (whether a human surgeon or a surgical robot), while the term “proximal” refers to the portion that is being described which is closer to the operator. Terms including “generally,” “about,” “substantially,” and the like, as utilized herein, are meant to encompass variations, e.g., manufacturing tolerances, material tolerances, use and environmental tolerances, measurement variations, design variations, and/or other variations, up to and including plus or minus 10 percent. To the extent consistent, any of the aspects described herein may be used in conjunction with any or all of the other aspects described herein.

[0006] Provided in accordance with aspects of this disclosure is a surgical instrument including a housing, a shaft assembly extending distally from the housing, and an end effector assembly extending distally from the shaft assembly. The end effector assembly includes first and second jaw members including respective first and second tissue contacting surfaces. At least one of the first or second jaw members is movable relative to the other of the first or second jaw members between a spaced apart position and an approximated position for grasping tissue between the first and second tissue contacting surfaces. The second jaw member includes a jaw housing tapering in height along a portion of a length of the jaw housing in a proximal to distal direction from a first height at a first position to a second height at a second position. The second jaw member further includes a cutting electrode engaged within the jaw housing and extending from the second tissue contacting surface towards the first jaw member. The cutting electrode tapers in height within the jaw housing along a portion of a length of the cutting electrode in a proximal to distal direction from a third height at the first position to a fourth height at the second position. The third height is less than the first height but greater than the second height, and the fourth height is less than the second height.

[0007] In an aspect of this disclosure, the cutting electrode defines an angled surface within the jaw housing, the angled surface defining the taper in height of the cutting electrode.

[0008] In another aspect of this disclosure, the taper in height of the cutting electrode begins proximal to the taper in height of the jaw housing. Alternatively, the taper in height of the cutting electrode may begin distal to the taper in height of the jaw housing. Further still, the tapers in height of the cutting electrode and the jaw housing may begin at substantially the same position.

[0009] In yet another aspect of this disclosure, the cutting electrode includes a substantially constant height portion defining the third height. The substantially constant height portion of the cutting electrode may partially overlap the taper in height of the jaw housing. Alternatively, the substantially constant height portion of the cutting electrode may not overlap the taper in height of the jaw housing. [0010] In still another aspect of this disclosure, the second jaw member is movable relative to at least a portion of the shaft assembly and the first jaw member, while the first jaw member is fixed relative to the portion of the shaft assembly.

[0011] An end effector assembly of a surgical instrument provided in accordance with this disclosure includes first and second jaw members including respective first and second tissue contacting surfaces. At least one of the first or second jaw members is movable relative to the other of the first or second jaw members between a spaced apart position and an approximated position for grasping tissue between the first and second tissue contacting surfaces. The second jaw member includes a jaw and a cutting electrode engaged within the jaw housing and extending through a slot defined within the second tissue contacting surface towards the first jaw member. The cutting electrode includes a proximal cutting electrode body and a distal cutting electrode tip extending from the proximal cutting electrode body to a distal end of the cutting electrode. The distal cutting electrode tip tapers in height within the jaw housing in a proximal to distal direction. [0012] In an aspect of this disclosure, the jaw housing includes a proximal jaw housing body and a distal jaw housing tip extending from the proximal jaw housing body to a distal end of the jaw housing. The proximal jaw housing body defines a first height and the distal jaw housing tip tapers in height from the proximal jaw housing body towards the distal end of the jaw housing such that the distal jaw housing tip defines a second height that is less than the first height.

[0013] In another aspect of this disclosure, the proximal cutting electrode body defines a third height within the jaw housing that is less than the first height and greater than the second height. The distal cutting electrode tip extends at least partially within a portion of the distal jaw housing tip that defines the second height. The distal cutting electrode tip defines a fourth height within the jaw housing that is less than the second height to enable the distal cutting electrode tip to extend at least partially within the portion of the distal jaw housing tip that defines the second height.

[0014] In an aspect of this disclosure, the third height of the proximal cutting electrode body is substantially constant along a length of the proximal cutting electrode body.

[0015] In another aspect of this disclosure, the distal cutting electrode tip defines an angled surface extending from the proximal cutting electrode body towards the distal end of the cutting electrode. The angled surface, in such aspects, defines the taper in height of the distal cutting electrode tip. [0016] In still another aspect of this disclosure, the taper in height of the distal cutting electrode tip begins within the proximal jaw housing body and extends to within the distal jaw housing tip. Alternatively, the taper in height of the distal cutting electrode tip begins within the distal jaw housing tip.

[0017] In yet another aspect of this disclosure, the cutting electrode extends along at least about 90% of a length of the second tissue contacting surface. In such aspects, the portion of the distal jaw housing tip that defines the second height, or a height less than the second height may extend along at least about 10% of a length of the second tissue contacting surface.

[0018] Another end effector assembly of a surgical instrument provided in accordance with this disclosure includes first and second jaw members including respective first and second tissue contacting surfaces. At least one of the first or second jaw members is movable relative to the other of the first or second jaw members between a spaced apart position and an approximated position for grasping tissue between the first and second tissue contacting surfaces. The second jaw member includes a jaw housing including a proximal jaw housing body defining a substantially constant height and a distal jaw housing tip tapering in height from the proximal jaw housing body towards a distal end of the jaw housing. A cutting electrode is engaged within the jaw housing and extends from the second tissue contacting surface towards the first jaw member. The cutting electrode includes a body extending within the proximal jaw housing body. The body of the cutting electrode includes a distal portion extending into the distal jaw housing tip. The cutting electrode further includes a plurality of retention tabs extending from the body of the cutting electrode and disposed within the proximal jaw housing body. The distal portion of the cutting electrode is devoid of a retention tab.

[0019] In an aspect of this disclosure, each retention tab of the plurality of retention tabs defines a through-hole to facilitate engagement of the cutting electrode within the jaw housing.

[0020] In still another aspect of this disclosure, the distal portion of the cutting electrode defines from about 25% to about 50% of a length of the cutting electrode.

[0021] In yet another aspect of this disclosure, the distal jaw housing tip tapers in height from a first height of the proximal jaw housing body to a second height less than the first height. In such aspects, the distal jaw housing tip defines the second height along a portion of a length thereof. [0022] In still yet another aspect of this disclosure, the body of the cutting electrode defines a third height within the jaw housing that is less than the second height. A fourth height defined by the body of the cutting electrode within the jaw housing plus a height of a retention tab of the plurality of retention tabs is greater than the second height but less than the first height.

BRIEF DESCRIPTION OF THE DRAWINGS

[0023] The above and other aspects and features of this disclosure will become more apparent in view of the following detailed description when taken in conjunction with the accompanying drawings wherein like reference numerals identify similar or identical elements.

[0024] FIG. 1 is a schematic illustration of a surgical robotic system including a control tower, a console, and one or more surgical robotic arms according to aspects of this disclosure;

[0025] FIG. 2 is a perspective view of a surgical robotic arm of the surgical robotic system of FIG. 1 according to aspects of this disclosure;

[0026] FIG. 3 is a perspective view of a setup arm with the surgical robotic arm of the surgical robotic system of FIG. 1 according to aspects of this disclosure;

[0027] FIG. 4 is a schematic diagram of a computer architecture of the surgical robotic system of FIG. 1 according to aspects of this disclosure;

[0028] FIG. 5 is a perspective view of a surgical instrument provided in accordance with the present disclosure configured for mounting on a robotic arm of a surgical robotic system such as the surgical robotic system of FIG. 1;

[0029] FIGS. 6A and 6B are front and rear perspective views, respectively, of a proximal portion of the surgical instrument of FIG. 5, with an outer shell removed;

[0030] FIG. 7 is a front perspective view of the proximal portion of the surgical instrument of FIG. 5 with the outer shell and additional internal components removed;

[0031] FIGS. 8 A and 8B are side views of a portion of the end effector assembly of the surgical instrument of FIG. 5 with jaw members of the end effector assembly disposed in spaced apart and approximated positions, respectively;

[0032] FIG. 9 is a transverse, cross-sectional view of the end effector assembly of the surgical instrument of FIG. 5;

[0033] FIG. 10 is a plan view of one of the jaw members of the end effector assembly of the surgical instrument of FIG. 5; [0034] FIG. 11 is a longitudinal, cross-sectional view of one of the jaw members of the end effector assembly of the surgical instrument of FIG. 5 according to aspects of this disclosure;

[0035] FIG. 12 is a longitudinal, cross-sectional view of another jaw member configured for use with the end effector assembly of the surgical instrument of FIG. 5 according to aspects of this disclosure; and

[0036] FIG. 13 is a longitudinal, cross-sectional view of still another jaw member configured for use with the end effector assembly of the surgical instrument of FIG. 5 according to aspects of this disclosure.

DETAILED DESCRIPTION

[0037] This disclosure provides surgical end effector assemblies and surgical instruments for energy-based tissue cutting. As described in detail below, the surgical end effector assemblies and surgical instruments of this disclosure are configured for use with a surgical robotic system, which may include, for example, a surgical console, a control tower, and one or more movable carts having a surgical robotic arm coupled to a setup arm. The surgical console receives user input through one or more interface devices, which are interpreted by the control tower as movement commands for moving the surgical robotic arm. The surgical robotic arm includes a controller, which is configured to process the movement command and to generate a torque command for activating one or more actuators of the robotic arm, which, in turn, move the robotic arm in response to the movement command. Those skilled in the art will understand that this disclosure, although described in connection with surgical robotic systems, may also be adapted for use with handheld surgical instruments such as, for example, endoscopic surgical instruments and/or open surgical instruments, whether manually operated or powered.

[0038] With reference to FIG. 1, a surgical robotic system 10 includes a control tower 20, which is connected to components of the surgical robotic system 10 including a surgical console 30 and one or more robotic arms 40. Each of the robotic arms 40 includes a surgical instrument 50, 51 removably coupled thereto. Each of the robotic arms 40 is also coupled to a movable cart 60.

[0039] The one or more surgical instruments 50, 51 may be configured for use during minimally invasive surgical procedures and/or open surgical procedures. In aspects, one of the surgical instruments 50 may be an endoscope, such as an endoscope camera 51, configured to provide a video feed for the clinician. In aspects, one of the surgical instruments 50 may be an energy based surgical instrument such as, for example, an energy-based forceps configured to seal tissue by grasping tissue between opposing structures and applying energy, e.g., electrical, thermal, ultrasonic, light, etc., energy thereto and to cut tissue by applying energy, e.g., electrical, thermal, ultrasonic, light, etc., energy thereto. An example of such an energy-based forceps for energybased sealing and cutting is described in detail below and identified by reference numeral 110 (FIG. 5).

[0040] Endoscope camera 51 is configured to capture video of the surgical site. The surgical console 30 includes a first display 32, which displays a video feed of the surgical site provided by endoscope camera 51, and a second display 34, which displays a user interface for controlling the surgical robotic system 10. The first and second displays 32 and 34 are touchscreens allowing for display of and interaction with various graphical user inputs.

[0041] The surgical console 30 also includes a plurality of user interface devices, such as foot pedals 36 and a pair of handle controllers 38a and 38b which are used by a user to remotely control robotic arms 40. The surgical console further includes an armrest 33 used to support clinician’s arms while operating the handle controllers 38a and 38b.

[0042] The control tower 20 includes a display 23, which may be a touchscreen, and outputs on the graphical user interfaces (GUIs). The control tower 20 also acts as an interface between the surgical console 30 and one or more robotic arms 40. In particular, the control tower 20 is configured to control the robotic arms 40, such as to move the robotic arms 40 and the corresponding surgical instrument 50, 51 based on a set of programmable instructions and/or input commands from the surgical console 30, in such a way that robotic arms 40 and the surgical instruments 50, 51 execute a desired movement sequence in response to input from the foot pedals 36 and the handle controllers 38a and 38b.

[0043] Each of the control tower 20, the surgical console 30, and the robotic arm 40 includes a respective computer 21, 31, 41. The computers 21, 31, 41 are interconnected to each other using any suitable communication network based on wired or wireless communication protocols. The term “network,” whether plural or singular, as used herein, denotes a data network, including, but not limited to, the Internet, Intranet, a wide area network, or a local area network, and without limitation as to the full scope of the definition of communication networks as encompassed by the present disclosure. Suitable protocols include, but are not limited to, transmission control protocol/internet protocol (TCP/IP), datagram protocol/internet protocol (UDP/IP), and/or datagram congestion control protocol (DCCP). Wireless communication may be achieved via one or more wireless configurations, e.g., radio frequency, optical, Wi-Fi, Bluetooth® (an open wireless protocol for exchanging data over short distances, using short length radio waves, from fixed and mobile devices, creating personal area networks (PANs)), ZigBee® (a specification for a suite of high level communication protocols using small, low-power digital radios based on the IEEE 122.15.4-2003 standard for wireless personal area networks (WPANs)).

[0044] The computers 21, 31, 41 may include any suitable processor (not shown) operably connected to a memory (not shown), which may include one or more of volatile, non-volatile, magnetic, optical, or electrical media, such as read-only memory (ROM), random access memory (RAM), electrically-erasable programmable ROM (EEPROM), non-volatile RAM (NVRAM), or flash memory. The processor may be any suitable processor (e.g., control circuit) adapted to perform the operations, calculations, and/or set of instructions described in the present disclosure including, but not limited to, a hardware processor, a field programmable gate array (FPGA), a digital signal processor (DSP), a central processing unit (CPU), a microprocessor, and combinations thereof. Those skilled in the art will appreciate that the processor may be substituted for by using any logic processor (e.g., control circuit) adapted to execute algorithms, calculations, and/or set of instructions described herein.

[0045] With reference to FIGS. 2 and 3, each of the robotic arms 40 may include a plurality of links 42a, 42b, 42c, which are interconnected at joints 44a, 44b, 44c, respectively. Joint 44a is configured to secure the robotic arm 40 to the movable cart 60 and defines a first longitudinal axis. The movable cart 60 includes a lift 61 and a setup arm 62, which provides a base for mounting of the robotic arm 40. The lift 61 allows for vertical movement of the setup arm 62. The movable cart 60 also includes a display 69 for displaying information pertaining to the robotic arm 40.

[0046] The setup arm 62 includes a first link 62a, a second link 62b, and a third link 62c, which provide for lateral maneuverability of the robotic arm 40. The links 62a, 62b, 62c are interconnected at joints 63a and 63b, each of which may include an actuator (not shown) for rotating the links 62a and 62b relative to each other and the link 62c. In particular, the links 62a, 62b, 62c are movable in their corresponding lateral planes that are parallel to each other, thereby allowing for extension of the robotic arm 40 relative to the patient (e.g., surgical table). In aspects, the robotic arm 40 may be coupled to the surgical table (not shown). The setup arm 62 includes controls 65 for adjusting movement of the links 62a, 62b, 62c as well as the lift 61. [0047] The third link 62c includes a rotatable base 64 having two degrees of freedom. In particular, the rotatable base 64 includes a first actuator 64a and a second actuator 64b. The first actuator 64a is rotatable about a first stationary arm axis which is perpendicular to a plane defined by the third link 62c and the second actuator 64b is rotatable about a second stationary arm axis which is transverse to the first stationary arm axis. The first and second actuators 64a and 64b allow for full three-dimensional orientation of the robotic arm 40.

[0048] With reference again to FIGS. 1 and 2, the robotic arm 40 also includes a holder 46 defining a second longitudinal axis and configured to receive an IDU 52. The IDU 52 is configured to couple to an actuation mechanism of the surgical instrument 50 and the endoscope camera 51 and is configured to move (e.g., rotate) and actuate the instrument 50 and/or the endoscope camera 51. IDU 52 transfers actuation forces from its actuators to the surgical instrument 50 and/or the endoscope camera 51to actuate components (e.g., end effectors) of the surgical instrument 50. The holder 46 includes a sliding mechanism 46a, which is configured to move the IDU 52 along the second longitudinal axis defined by the holder 46. The holder 46 also includes a joint 46b, which rotates the holder 46 relative to the link 42c.

[0049] The robotic arm 40 further includes a plurality of manual override buttons 53 disposed on the IDU 52 and/or the setup arm 62, which may be used in a manual mode. The clinician may press one or the buttons 53 to move the component associated with the button 53.

[0050] The joints 44a and 44b include an actuator 48a and 48b configured to drive the joints 44a, 44b, 44c relative to each other through a series of belts 45a and 45b or other mechanical linkages such as a drive rod, a cable, or a lever and the like. In particular, the actuator 48a is configured to rotate the robotic arm 40 about a longitudinal axis defined by the link 42a.

[0051] The actuator 48b of the joint 44b is coupled to the joint 44c via the belt 45a, and the joint 44c is in turn coupled to the joint 46c via the belt 45b. Joint 44c may include a transfer case coupling the belts 45a and 45b, such that the actuator 48b is configured to rotate each of the links 42b, 42c and the holder 46 relative to each other. More specifically, links 42b, 42c, and the holder 46 are passively coupled to the actuator 48b which enforces rotation about a remote center point “P” which lies at an intersection of the first axis defined by the link 42a and the second axis defined by the holder 46. Thus, the actuator 48b controls the angle “A” between the first and second axes allowing for orientation of the surgical instrument 50. Due to the interlinking of the links 42a, 42b, 42c, and the holder 46 via the belts 45a and 45b, the angles between the links 42a, 42b, 42c, and the holder 46 are also adjusted in order to achieve the desired angle “A.” In aspects, some or all of the joints 44a, 44b, 44c may include an actuator to obviate the need for mechanical linkages. [0052] With reference to FIGS. 1 and 4, each of the computers 21, 31, 41 of the surgical robotic system 10 may include a plurality of controllers, which may be embodied in hardware and/or software. The computer 21 of the control tower 20 includes a controller 21a and safety observer 21b. The controller 21a receives data from the computer 31 of the surgical console 30 about the current position and/or orientation of the handle controllers 38a and 38b and the state of the foot pedals 36 and other buttons. The controller 21a processes these input positions to determine desired drive commands for each joint of the robotic arm 40 and/or the IDU 52 and communicates these to the computer 41 of the robotic arm 40. The controller 21a also receives back the actual joint angles and uses this information to determine force feedback commands that are transmitted back to the computer 31 of the surgical console 30 to provide haptic feedback through the handle controllers 38a and 38b. The handle controllers 38a and 38b include one or more haptic feedback vibratory devices that output haptic feedback. The safety observer 21b performs validity checks on the data going into and out of the controller 21a and notifies a system fault handler if errors in the data transmission are detected to place the computer 21 and/or the surgical robotic system 10 into a safe state.

[0053] The computer 41 includes a plurality of controllers, namely, a main cart controller 41a, a setup arm controller 41b, a robotic arm controller 41c, and an IDU controller 41 d. The main cart controller 41a receives and processes joint commands from the controller 21a of the computer 21 and communicates them to the setup arm controller 41b, the robotic arm controller 41c, and the IDU controller 41 d. The main cart controller 41a also manages instrument exchanges and the overall state of the movable cart 60, the robotic arm 40, and the IDU 52. The main cart controller 41a also communicates actual joint angles back to the controller 21a.

[0054] With additional reference to FIGS. 2 and 3, the setup arm controller 41b controls each of joints 63a and 63b, and the rotatable base 64 of the setup arm 62 and calculates desired motor movement commands (e.g., motor torque) for the pitch axis and controls the brakes. The robotic arm controller 41c controls each joint 44a and 44b of the robotic arm 40 and calculates desired motor torques required for gravity compensation, friction compensation, and closed loop position control of the robotic arm 40. The robotic arm controller 41c calculates a movement command based on the calculated torque. The calculated motor commands are then communicated to one or more of the actuators 48a and 48b in the robotic arm 40. The actual joint positions are then transmitted by the actuators 48a and 48b back to the robotic arm controller 41c.

[0055] The IDU controller 41 d receives desired joint angles for the surgical instrument 50, such as wrist and jaw angles, and computes desired currents for the motors in the IDU 52. The IDU controller 41 d calculates actual angles based on the motor positions and transmits the actual angles back to the main cart controller 41a.

[0056] The robotic arm 40 is controlled as follows. Initially, a pose of the handle controller controlling the robotic arm 40, e.g., the handle controller 38a, is transformed into a desired pose of the robotic arm 40 through a hand eye transform function executed by the controller 21a. The hand eye function, as well as other functions described herein, is/are embodied in software executable by the controller 21a or any other suitable controller described herein. The pose of the handle controller 38a may be embodied as a coordinate position and role-pitch-yaw (“RPY”) orientation relative to a coordinate reference frame, which is fixed to the surgical console 30. The desired pose of the instrument 50 is relative to a fixed frame on the robotic arm 40. The pose of the handle controller 38a is then scaled by a scaling function executed by the controller 21a. In aspects, the coordinate position is scaled down and the orientation is scaled up by the scaling function. In addition, controller 21a also executes a clutching function, which disengages the handle controller 38a from the robotic arm 40. In particular, the controller 21a stops transmitting movement commands from the handle controller 38a to the robotic arm 40 if certain movement limits or other thresholds are exceeded and in essence acts like a virtual clutch mechanism, e.g., limits mechanical input from effecting mechanical output.

[0057] The desired pose of the robotic arm 40 is based on the pose of the handle controller 38a and is then passed by an inverse kinematics function executed by the controller 21a. The inverse kinematics function calculates angles for the joints 44a, 44b, 44c of the robotic arm 40 that achieve the scaled and adjusted pose input by the handle controller 38a. The calculated angles are then passed to the robotic arm controller 41c, which includes a joint axis controller having a proportional-derivative (PD) controller, the friction estimator module, the gravity compensator module, and a two-sided saturation block, which is configured to limit the commanded torque of the motors of the joints 44a, 44b, 44c.

[0058] Turning to FIGS. 5-7, a surgical instrument 110 provided in accordance with the present disclosure generally includes a housing 120, a shaft 130 extending distally from housing 120, an end effector assembly 140 extending distally from shaft 130, and an actuation assembly 1100 disposed within housing 120 and operably associated with end effector assembly 140. Instrument 110 is detailed herein as an articulating electrosurgical forceps configured for use with a surgical robotic system, e.g., surgical robotic system 10 (FIG. 1). However, the aspects and features of instrument 110 provided in accordance with the present disclosure, detailed below, are equally applicable for use with other suitable surgical instruments, e.g., graspers, staplers, clip appliers, and/or in other suitable surgical systems, e.g., motorized, other power driven systems, and/or manually actuated surgical systems (including handheld instruments).

[0059] With particular reference to FIG. 5, housing 120 of instrument 110 includes first and second housing parts 122a, 122b and a proximal face plate 124 that cooperate to enclose actuation assembly 1100 therein. Proximal face plate 124 includes through holes defined therein through which input couplers 1110-1140 (FIG. 6B) of actuation assembly 1100 extend. A pair of latch levers 126 (only one of which is illustrated in FIG. 5) extending outwardly from opposing sides of housing 120 enable releasable engagement of housing 120 with a robotic arm 40 (FIG. 1) of a surgical robotic system, e.g., surgical robotic system 10 (FIG. 1). A window 128 defined through housing 120 permits thumbwheel 1440 to extend therethrough to enable manual manipulation of thumbwheel 1440 from the exterior of housing 120 to permit manual opening and closing of end effector assembly 140.

[0060] Referring also to FIGS. 6A-7, a plurality of electrical contacts 190 extend through one or more apertures defined through proximal face plate 124 to enable electrical communication between instrument 110 and surgical robotic system 10 (FIG. 1) when instrument 110 is engaged on a robotic arm thereof, e.g., for the communication of data, control, and/or power signals therebetween. As an alternative to electrical contacts 190 extending through proximal face plate 124, other suitable transmitter, receiver, and/or transceiver components to enable the communication of data, control, and/or power signals are also contemplated, e.g., using RFID, Bluetooth®, WiFi®, or via any other suitable wired, wireless, contacted, or contactless communication method. At least some of the electrical contacts 190 are electrically coupled with electronics 192 mounted on an interior side of proximal face plate 124, e.g., within housing 120. Electronics 192 may include, for example, a storage device, a communications device (including suitable input/output components), and a CPU including a memory and a processor. Electronics 192 may be mounted on a circuit board or otherwise configured, e.g., as a chip.

[0061] The storage device of electronics 192 stores information relating to surgical instrument such as, for example: the item number, e.g., SKU number; date of manufacture; manufacture location, e.g., location code; serial number; lot number; use information; setting information; adjustment information; calibration information; security information, e.g., encryption key(s), and/or other suitable additional or alternative data. The storage device of electronics 192 may be, for example, a magnetic disk, flash memory, optical disk, or other suitable data storage device.

[0062] As an alternative or in addition to storing the above noted information in the storage device of electronics 192, some or all of such information, e.g., the use information, calibration information, setting information, and/or adjustment information, may be stored in a storage device associated with surgical robotic system 10 (FIG. 1), a remote server, a cloud server, etc., and accessible via instrument 110 and/or surgical robotic system 10 (FIG. 1). In such configurations, the information may, for example, be updated by manufacturer provided updates, and/or may be applied to individual instruments, units of instruments (e.g., units from the same manufacturing location, manufacturing period, lot number, etc.), or across all instruments. Further still, even where the information is stored locally on each instrument, this information may be updated by manufacturer provided updates manually or automatically upon connection to the surgical robotic system 10 (FIG. 1).

[0063] Referring again to FIG. 5, shaft 130 of instrument 110 includes a distal clevis segment 132, a proximal segment 134, and an articulating section 136 disposed between the distal clevis and proximal segments 132, 134, respectively. Articulating section 136 includes one or more articulating components 137, e.g., links, joints, etc. A plurality of articulation cables 138, e.g., four (4) articulation cables, or other suitable actuators, extend through articulating section 136. More specifically, articulation cables 138 are operably coupled to distal clevis segment 132 of shaft 130 at the distal ends thereof and extend proximally from distal clevis segment 132 of shaft 130, through articulating section 136 of shaft 130 and proximal segment 134 of shaft 130, and into housing 120, wherein articulation cables 138 operably couple with an articulation sub-assembly 1200 of actuation assembly 1100 (FIG. 6A) to enable selective articulation of distal clevis segment 132 (and, thus end effector assembly 140) relative to proximal segment 134 and housing 120, e.g., about at least two axes of articulation (yaw and pitch articulation, for example). Articulation cables 138 are arranged in a generally rectangular configuration, although other suitable configurations are also contemplated. In some configurations, as an alternative, shaft 130 is substantially rigid, malleable, or flexible and not configured for active articulation. Articulation sub-assembly 1200 is described in greater detail below.

[0064] With respect to articulation of end effector assembly 140 relative to proximal segment 134 of shaft 130, actuation of articulation cables 138 may be accomplished in pairs. More specifically, in order to pitch end effector assembly 140, the upper pair of cables 138 are actuated in a similar manner while the lower pair of cables 138 are actuated in a similar manner relative to one another but an opposite manner relative to the upper pair of cables 138. With respect to yaw articulation, the right pair of cables 138 are actuated in a similar manner while the left pair of cables 138 are actuated in a similar manner relative to one another but an opposite manner relative to the right pair of cables 138. Other configurations of articulation cables 138 or other articulation actuators are also contemplated.

[0065] Continuing with reference to FIG. 5, end effector assembly 140 includes first and second jaw members 142, 144, respectively. Each jaw member 142, 144 includes a proximal flange 143a, 145a and a distal body 143b, 145b, respectively. Distal bodies 143b, 145b define opposed tissue contacting surfaces 146, 148, respectively. Proximal flanges 143a, 145a are pivotably coupled to one another about a pivot 150 and are operably coupled to one another via a cam slot assembly 152 including a cam pin slidably received within cam slots defined within the proximal flange 143a, 145a of at least one of the jaw members 142, 144, respectively, to enable pivoting of jaw member 142 relative to jaw member 144 and distal segment 132 of shaft 130 between a spaced apart position (e.g., an open position of end effector assembly 140) and an approximated position (e.g., a closed position of end effector assembly 140) for grasping tissue between tissue contacting surfaces 146, 148. As an alternative to this unilateral configuration, a bilateral configuration may be provided whereby both jaw members 142, 144 are pivotable relative to one another and distal segment 132 of shaft 130. Alternatively, the above detailed configuration may be reversed, e.g., wherein jaw member 142 is the fixed jaw member and jaw member 144 is movable relative to jaw member 142. Other suitable jaw actuation mechanisms (for bilateral and/or unilateral jaw configurations) are also contemplated.

[0066] In configurations, jaw member 144 supports a longitudinally extending cutting electrode 149 in a slot 160 defined through tissue contacting surface 148, while jaw member 142 includes a compression pad 162 (FIG. 9) disposed in a slot 161 defined through tissue contacting surface 146. In such aspects, in the approximated position of jaw members 142, 144, cutting electrode 149 is urged into contact with compression pad 162 (FIG. 9) to grasp and tension tissue therebetween. Cutting electrode 149 may then be energized to cut the tissue disposed between cutting electrode 149 and compression pad 162 (FIG. 9). Cutting electrode 149 may additionally or alternatively be used to cut tissue in an open jaw configuration, e.g., with jaw members 142, 144 disposed in the spaced apart position. Cutting electrode 149 may be configured to be energized with monopolar Radio Frequency (RF) energy from a surgical generator (not shown) to conduct RF energy to tissue to cut the tissue, wherein the RF energy is returned to the generator complete the circuit via a remote return device such as a return pad (not shown). Alternatively or additionally, cutting electrode 149 may be energized with bipolar RF energy wherein energy conducted from cutting electrode 149 to tissue is returned via either or both of tissue contacting surfaces 146, 148 of jaw members 142, 144, respectively, or other suitable local return device. Instead of an RF-based cutting electrode 149, other suitable energy-based cutting elements are also contemplated such as, for example, an ultrasonic blade, thermal cutting element, microwave cutting element, light-based cutting element, combinations thereof, etc.

[0067] Referring still to FIG. 5, a drive rod 1484 is operably coupled to cam slot assembly 152 of end effector assembly 140, e.g., engaged with the cam pin thereof, such that longitudinal actuation of drive rod 1484 pivots j aw member 142 relative to j aw member 144 between the spaced apart and approximated positions. More specifically, urging drive rod 1484 proximally pivots jaw member 142 relative to jaw member 144 towards the approximated position while urging drive rod 1484 distally pivots jaw member 142 relative to jaw member 144 towards the spaced apart position. However, other suitable mechanisms and/or configurations for pivoting jaw member 142 relative to jaw member 144 between the spaced apart and approximated positions in response to selective actuation of drive rod 1484 are also contemplated. Drive rod 1484 extends proximally from end effector assembly 140 through shaft 130 and into housing 120 wherein drive rod 1484 is operably coupled with a jaw drive sub-assembly 1400 of actuation assembly 1100 (FIGS. 6A-6B) to enable selective actuation of end effector assembly 140 to grasp tissue therebetween and apply a jaw force within an appropriate jaw force range.

[0068] Tissue contacting surfaces 146, 148 of jaw members 142, 144, respectively, are at least partially formed from an electrically conductive material and are energizable to different potentials to enable the conduction of RF electrical energy through tissue grasped therebetween, although tissue contacting surfaces 146, 148 may alternatively be configured to supply any suitable energy, e.g., thermal, microwave, light, ultrasonic, etc., through tissue grasped therebetween for energy based tissue treatment. Instrument 110 defines a conductive pathway (not shown) through housing 120 and shaft 130 to end effector assembly 140 that may include lead wires, contacts, and/or electrically conductive components to enable electrical connection of tissue contacting surfaces 146, 148 of jaw members 142, 144, respectively, to an energy source (not shown), e.g., an electrosurgical generator, for supplying energy to tissue contacting surfaces 146, 148 to treat, e.g., seal, tissue grasped between tissue contacting surfaces 146, 148.

[0069] With additional reference to FIGS. 6A-7, as noted above, actuation assembly 1100 is disposed within housing 120 and includes an articulation sub-assembly 1200, and a jaw drive subassembly 1400. Articulation sub-assembly 1200 is operably coupled between first and second input couplers 1110, 1120, respectively, of actuation assembly 1100 and articulation cables 138 (FIG. 5) such that, upon receipt of appropriate inputs into first and/or second input couplers 1110, 1120, articulation sub-assembly 1200 manipulates cables 138 (FIG. 5) to articulate end effector assembly 140 in a desired direction, e.g., to pitch and/or yaw end effector assembly 140. Articulation sub-assembly 1200 is described in greater detail below.

[0070] Jaw drive sub-assembly 1400 is operably coupled between fourth input coupler 1140 of actuation assembly 1100 and drive rod 1484 such that, upon receipt of appropriate input into fourth input coupler 1140, jaw drive sub-assembly 1400 pivots jaw members 142, 144 between the spaced apart and approximated positions to grasp tissue therebetween and apply a jaw force within an appropriate jaw force range.

[0071] Actuation assembly 1100 is configured to operably interface with a surgical robotic system, e.g., system 10 (FIG. 1), when instrument 110 is mounted on a robotic arm thereof, to enable robotic operation of actuation assembly 1100 to provide the above detailed functionality. That is, surgical robotic system 10 (FIG. 1) selectively provides inputs, e.g., rotational inputs to input couplers 1110-1140 of actuation assembly 1100 to articulate end effector assembly 140, grasp tissue between jaw members 142, 144, and/or cut tissue grasped between jaw members 142, 144. However, as noted above, it is also contemplated that actuation assembly 1100 be configured to interface with any other suitable surgical systems, e.g., a manual surgical handle, a powered surgical handle, etc.

[0072] Turning to FIGS. 8A, 8B, and 9, a distal portion of end effector assembly 140 is shown with jaw members 142, 144 disposed in the spaced apart position (FIG. 8 A) and the approximated position (FIGS. 8B and 9). In aspects, either or both tissue contacting surfaces 146, 148 of jaw members 142, 144, respectively, are defined by respective tissue contacting plates 166, 168 disposed on the opposing surfaces of distal bodies 143b, 145b of jaw members 142, 144, respectively. As detailed above, jaw member 144 supports cutting electrode 149 in slot 160 defined through tissue contacting surface 148 (and through tissue contacting plate 168), while jaw member 142 includes compression pad 162 disposed in slot 161 defined through tissue contacting surface 146 (and through tissue contacting plate 166) and configured to oppose cutting electrode 149 in the approximated position of jaw members 142, 144 (FIGS. 8B and 9). Tissue contacting surfaces 146, 148 may define substantially U-shaped configurations wherein the slots 161, 162 defined therethrough terminate at positions proximally spaced from the distal ends of tissue contact surfaces 148, 148 (see, e.g., tissue contacting surface 148 (FIG. 10)).

[0073] Cutting electrode 149 protrudes from jaw member 144 beyond tissue contacting plate 168 and towards jaw member 142. Compression pad 162 may be substantially flush with tissue contacting surface 146 of tissue contacting plate 166, may be recessed relative thereto (as shown), or may protrude from tissue contacting surface 146 of tissue contacting plate 166 towards jaw member 144. Cutting electrode 149 and compression pad 162 are configured, and compression pad 162 defines a suitable durometer, such that, in the approximated position of jaw members 142, 44 (see FIGS. 8B and 9), cutting electrode 149 is urged into and at least partially compresses compression pad 162 (with tissue grasped and tensioned therebetween). This contact between cutting electrode 149 and compression pad 162 may also maintain a spacing between tissue contacting surfaces 146, 148 to inhibit electrical shorting via contact therebetween.

[0074] Either or both jaw members 142, 144 may include a structural jaw support 172, 174 defining the respective proximal flange 143a, 145a of the jaw member 142, 144 and extending into the respective distal body 143b, 145b. In such configurations, distal body 143b, 145b of either or both jaw members 142, 144 may further include jaw housings 173, 175 surrounding structural jaw supports 172, 174 and supporting tissue contacting plates 166, 168, respectively, thereon. Jaw housings 173, 175 may be formed from insulative materials and, in aspects, may be overmolded about jaw supports 172, 174 and a portion of tissue contacting plates 166, 168 to form jaw members 142, 144 and secure the components thereof to one another. In other configurations, jaw housings 173, 175 are conductive and electrically isolated from the other components of jaw members 142, 144 via suitable insulation. Alternatively or additionally, either or both jaw members 142, 144 may be formed from a monolithic, electrically conductive piece of material defining the structural jaw support, tissue contacting surface, and jaw housing thereof. At least a portion of the jaw housing, in such configurations, may be coated with an insulative material. Further, with respect to configurations where jaw member 144 is formed from a monolithic piece of material, cutting electrode 149 may be electrically isolated from the remainder of jaw member 144, e.g., via an insulator disposed therebetween. Thus, as utilized herein, reference to jaw housings 173, 175 includes insulative jaw housings, conductive jaw housings, and/or monolithic jaw structures defining jaw housings. Further, both jaw members 142, 144 may be similarly configured or may define different configurations, such as any combination of the jaw configurations detailed herein. [0075] Continuing with reference to FIGS. 8A and 8B, jaw housings 173, 175 define the outer profiles of jaw members 142, 144, respectively. In aspects, jaw housings 173, 175 include bodies 176, 178 each defining heights “Hl,” “H2” (similar or different from one another) sufficient to provide structural support to respective jaw members 142, 144 (thus inhibiting or reducing jaw flexion, for example), and to facilitate retention of compression pad 162 and cutting electrode 149, respectively, therein. However, while relatively greater heights “Hl,” “H2” of jaw housing 173, 175 provide greater structural support and facilitate retention, reduced height at the distal tips of jaw members 142, 144 facilitates blunt dissection of tissue, separating tissue layers, and the “poke and spread” technique, wherein jaw members 142, 144 are urged into tissue in the approximated position and subsequently moved to the spaced apart position to spread the tissue apart.

[0076] Accordingly, jaw members 142, 144 define reduced height distal tips 177, 179, respectively, as compared to respective proximal bodies 176, 178. Reduced height distal tips 177, 179 may include one or more curved and/or angled surfaces disposed between proximal bodies 176, 178 and the distal ends of jaw members 142, 144, respectively, such that tips 177, 179 define heights “hl ,” “h2” (similar or different from one another) less than “Hl ,” “H2” of bodies 176, 178. Heights “hl,” “h2” may be defined by substantially constant height longitudinal extents of tip sections 177, 179 connected to bodies 176, 178 via one or more curved and/or angled surfaces (as shown in FIGS. 8A and 8B). However, heights “hl,” “h2” need not be constant for the entire, or any, longitudinal extent of tip sections 177, 179 of jaw housings 173, 175 but, rather, may curve, step, and/or taper from bodies 176, 178 to the distal ends of jaw members 142, 144. Thus, heights “hl,” “h2,” may be defined as the average heights of tips 177, 179. Likewise, bodies 176, 178 need not define constant heights; rather, heights “Hl,” “H2” may be defined as the average or minimum heights of bodies 176, 178 in such configurations.

[0077] While reduced height tips 177, 179 facilitate blunt dissection of tissue, separating tissue layers, and the “poke and spread” technique, the reduced heights “hl,” “h2” of tips 177, 179 present a challenge with respect to extending cutting electrode 149 (and in aspects, compression pad 162) distally into reduced height tips 177, 179. In aspects, tips 177, 179 may define at least about 15% of the lengths of distal bodies 143b, 145b of jaw members 142, 144; in other aspects, at least about 20% of the lengths of distal bodies 143b, 145b of jaw members 142, 144; and, in still other aspects, at least about 25% of the lengths of distal bodies 143b, 145b of jaw members 142, 144. Thus, terminating cutting electrode 149 (and in aspects, compression pad 162) proximally of tips 177, 179 would render a significant portion of end effector assembly 140 unavailable for cutting tissue using cutting electrode 149.

[0078] In order to address the above considerations, cutting electrode 149 may be designed to enable sufficient retention thereof within jaw member 144 while also permitting cutting electrode 149 to extend at least partially into reduced height tip 179 of jaw member 144 (thus enabling tissue cutting using cutting electrode 149 along substantially the entire length of distal body 145b of jaw member 144) and maintaining sufficient isolation of cutting electrode 149 from other conductive structure(s) of jaw member 144. Exemplary configurations are detailed below with reference to FIGS. 11-13. Aspects and features thereof, although described separately, may be utilized interchangeably to the extent consistent.

[0079] Referring to FIG. 11, a configuration of jaw member 144 is shown including a jaw housing 1175 defining a body 1178 and a tip 1179, e.g., according to any of the configurations detailed herein or any other suitable configuration. Cutting electrode 1149 is supported within jaw housing 1175 and protrudes therefrom towards jaw member 142 (FIGS. 8A-9). In aspects, cutting electrode 1149 protrudes a substantially constant distance from jaw housing 1175 along the length of tissue contacting surface 148 (FIGS. 8A and 8B). Further, cutting electrode 1149 may extend along at least 80% of a length of tissue contacting surface 148 (FIGS. 8A and 8B); in aspects, at least 85% of a length of tissue contacting surface 148 (FIGS. 8A and 8B); and in still other aspects, at least 90% of a length of tissue contacting surface 148 (FIGS. 8A and 8B).

[0080] Cutting electrode 1149 includes a body 1150a and a distal tip 1150b. Body 1150a of cutting electrode 1149 extends along body 1178 of jaw housing 1175 and, in aspects, partially into tip 1179 of jaw housing 1175. In aspects, the part of body 1150a that is disposed within jaw member 144 (i.e., not including the portion that protrudes towards jaw member 142 (FIGS. 8A and 8B)) defines a height “Hb” greater than a height limit “HL” of cutting electrode 1149 permitted in at least a section of tip 1179 of jaw housing 1175. This height limit “HL” may be defined as the height of jaw housing 1175 minus any required clearance or spacing such as, for example, the at least 0.010 inches insulative spacing “S” required between cutting electrode 1149 and the exterior surface of jaw housing 1175 and/or other conductive structures to inhibit energy transfer therebetween. Height “Hb” may be, for example, a substantially constant height of body 1150a of cutting electrode 1149, a minimum height of body 1150a of cutting electrode 1149, or an average height of body 1150a of cutting electrode 1149.

[0081] Distal tip 1150b of cutting electrode 1149 extends within tip 1179 of jaw housing 1175 and defines a tapering height in the proximal to distal direction. This tapering in height may be continuous (e.g., angled or curved) or stepped and may be formed from one or more curved and/or angled surfaces. Regardless of the particular configuration of this tapering in height distal tip 1150b of cutting electrode 1140 tapers such that at least a section of distal tip 1150b of cutting electrode 1149 defines a height less than the height limit “HL” of jaw housing 1175 in tip 1179 thereof. Thus, this tapered configuration enables at least a section of distal tip 1150b of cutting electrodes 1149 to extend into the height limited section of tip 1179 of jaw housing 1175. As such, cutting electrode 1149 is permitted to extend further towards the distal end of jaw member 144.

[0082] With reference to FIG. 12, another configuration of jaw member 144 is shown including a jaw housing 1275 defining a body 1278 and a tip 1279, e.g., according to any of the configurations detailed herein or any other suitable configuration. Cutting electrode 1249 is supported within jaw housing 1275 and protrudes therefrom towards jaw member 142 (FIGS. 8A- 9). In aspects, cutting electrode 1249 protrudes a substantially constant distance from jaw housing 1275 along the length of tissue contacting surface 148 (FIGS. 8A and 8B). Further, cutting electrode 1249 extends along at least 80% of a length of tissue contacting surface 148 (FIGS. 8 A and 8B); in aspects, at least 85% of a length of tissue contacting surface 148 (FIGS. 8A and 8B); and in still other aspects, at least 90% of a length of tissue contacting surface 148 (FIGS. 8A and 8B).

[0083] Cutting electrode 1249 includes a body 1250a and a distal tip 1250b. Body 1250a of cutting electrode 1249 extends along a proximal section of body 1278 of jaw housing 1275. In aspects, the part of body 1250a that is disposed within jaw member 144 (i.e., not including the portion that protrudes towards jaw member 142 (FIGS. 8 A and 8B)) defines a height “Hb” greater than a height limit “HL” of cutting electrode 1249 permitted in at least a section of tip 1279 of jaw housing 1275, similarly as detailed above with respect to cutting electrode 1149 (FIG. 11).

[0084] Distal tip 1250b of cutting electrodes 1249 extends from body 1250a within body 1278 of jaw housing 1275 through at least a section of tip 1279 of jaw housing 1275 and defines a tapering height in the proximal to distal direction. This tapering in height may be continuous or stepped and may be formed from one or more curved and/or angled surfaces. As a result of this tapered configuration of at least a section of distal tip 1250b of cutting electrodes 1249, cutting electrode 1249 is permitted to extend into the height limited section of tip 1279 of jaw housing 1274, thus enabling cutting electrode 1249 to extend further towards the distal end of jaw member 144.

[0085] Referring to FIGS. 11 and 12, as demonstrated above, cutting electrode 1249 (FIG. 12) differs from cutting electrode 1149 (FIG. 11) in that distal tip 1250b of cutting electrode 1249 starts within body 1278 of jaw housing 1275 and extends into tip 1279 of jaw housing 1275, while body 1150a of cutting electrode 1149 extends into tip 1179 of jaw housing 1275 such that distal tip 1150b of cutting electrode 1149 only extends within tip 1179 of jaw housing 1175.

[0086] Turning to FIG. 13, still another configuration of jaw member 144 is shown including a jaw housing 1375 defining a body 1378 and a tip 1379, e.g., according to any of the configurations detailed herein or any other suitable configuration. Cutting electrode 1349 is supported within jaw housing 1375 and protrudes therefrom towards jaw member 142 (FIGS. 8A- 9). In aspects, cutting electrode 1349 protrudes a substantially constant distance from jaw housing 1375 along the length of tissue contacting surface 148 (FIGS. 8A and 8B), similarly as detailed above with respect to cutting electrode 1149 (FIG. 11).

[0087] Cutting electrode 1349 includes a body 1350 that extends along body 1378 of jaw housing 1375 and at least partially along tip 1379 of jaw housing 1375. Body 1350 extends the length of cutting electrode 1349. In aspects, body 1350 defines a substantially constant height along its length, although body 1350 may also taper in height over at least a portion of the length thereof, e.g., similarly as detailed above with respect to cutting electrodes 1149, 1249 (FIGS .11 and 12, respectively). Cutting electrode 1349 defines a height “hb” (e.g., a constant height, a minimum height, a maximum height, or an average height) less than or equal to a height limit “HL” of cutting electrode 1349 permitted in at least a section of tip 1379 of jaw housing 1375 (similarly as detailed above with respect to cutting electrode 1149 (FIG. 11)) such that cutting electrode 1349 is permitted to extend through at least a section of tip 1379 of jaw housing 1375. [0088] Cutting electrode 1349 further includes a plurality of retention tabs 1380 depending from body 1350 and spaced apart along a portion of a length of body 1350 of cutting electrode 1349. Retention tabs 1380 are disposed within body 1378 of jaw housing 1375 and may define through-holes 1382 and/or other suitable mechanical features to facilitate engagement of cutting electrode 1349 within jaw housing 1375. Through-holes 1382, for example, enable the inflow of overmold material therethrough during formation of jaw housing 1375 (or a portion thereof) to secure cutting electrode 1349 relative to jaw housing 1375. In other configurations, retention tabs 1380 may include other suitable mechanical features to engage jaw housing 1375, structural jaw support 1372, and/or any other component of jaw member 144. Regardless of the particular manner of engagement, retention tabs 1380 facilitate engagement of cutting electrode 1349 within jaw member 144 despite the height constraint on body 1350 of cutting electrode 1349, e.g., based upon the height limit “HL” of cutting electrode 1349 permitted in at least a section of tip 1379 of jaw housing 1375.

[0089] The height of cutting electrode 1349 at a retention tab 1380, defined as the height of the portion of body 1350 disposed within jaw housing 1375 plus the height of the retention tab 1380, is greater than the height limit “HL” and, thus, retention tabs 1380 are disposed within body 1378 of jaw housing 1375 without extending into tip 1379 of jaw housing 1375 or extending minimally into tip 1379. As a result, cutting electrode 1349 may define a cantilever or cantileverlike configuration wherein a plurality of retention tabs 1380 are spaced-apart along a proximal portion of no more than about 75% of a length of cutting electrode 1349; in aspects, no more than about 62% of a length of cutting electrode 1349; and, in still other aspects, no more than about 1 50% of a length of cutting electrode 1349, while the remaining distal portion of cutting electrode 1349 does not include any retention tabs 1380.

[0090] While several aspects of this disclosure have been shown in the drawings, it is not intended that this disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular aspects. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.

Claims

WHAT IS CLAIMED IS:

1. A surgical instrument, comprising: a housing; a shaft assembly extending distally from the housing; and an end effector assembly extending distally from the shaft assembly, the end effector assembly including: first and second jaw members including respective first and second tissue contacting surfaces, at least one of the first or second jaw members movable relative to the other of the first or second jaw members between a spaced apart position and an approximated position for grasping tissue between the first and second tissue contacting surfaces, the second jaw member including: a jaw housing tapering in height along a portion of a length of the jaw housing in a proximal to distal direction from a first height at a first position to a second height at a second position; and a cutting electrode engaged within the jaw housing and extending from the second tissue contacting surface towards the first jaw member, the cutting electrode tapering in height within the jaw housing along a portion of a length of the cutting electrode in a proximal to distal direction from a third height at the first position to a fourth height at the second position, wherein the third height is less than the first height but greater than the second height, and wherein the fourth height is less than the second height.

2. The surgical instrument according to claim 1, wherein the cutting electrode defines an angled surface within the jaw housing, the angled surface defining the taper in height of the cutting electrode.

3. The surgical instrument according to claim 1 , wherein the taper in height of the cutting electrode begins proximal to the taper in height of the jaw housing.

4. The surgical instrument according to claim 1 , wherein the taper in height of the cutting electrode begins distal to the taper in height of the jaw housing.

5. The surgical instrument according to claim 1, wherein the cutting electrode includes a substantially constant height portion defining the third height.

6. The surgical instrument according to claim 5, wherein the substantially constant height portion of the cutting electrode partially overlaps the taper in height of the jaw housing.

7. The surgical instrument according to claim 5, wherein the substantially constant height portion of the cutting electrode does not overlap the taper in height of the jaw housing.

8. The surgical instrument according to claim 1, wherein the second jaw member is movable relative to at least a portion of the shaft assembly and the first jaw member, and wherein the first jaw member is fixed relative to the portion of the shaft assembly.

9. An end effector assembly of a surgical instrument, comprising: first and second jaw members including respective first and second tissue contacting surfaces, at least one of the first or second jaw members movable relative to the other of the first or second jaw members between a spaced apart position and an approximated position for grasping tissue between the first and second tissue contacting surfaces, the second jaw member including: a jaw housing; and a cutting electrode engaged within the jaw housing and extending through a slot defined within the second tissue contacting surface towards the first jaw member, the cutting electrode including a proximal cutting electrode body and a distal cutting electrode tip extending from the proximal cutting electrode body to a distal end of the cutting electrode, wherein the distal cutting electrode tip tapers in height within the jaw housing in a proximal to distal direction, and wherein the cutting electrode extends along at least about 90% of a length of the second tissue contacting surface.

10. The end effector assembly according to claim 9, wherein: the jaw housing includes a proximal jaw housing body and a distal jaw housing tip extending from the proximal jaw housing body to a distal end of the jaw housing, the proximal jaw housing body defining a first height, the distal jaw housing tip tapering in height from proximal jaw housing body towards the distal end of the jaw housing such that the distal jaw housing tip defines a second height that is less than the first height; and the proximal cutting electrode body defines a third height within the jaw housing that is less than the first height and greater than the second height, and wherein the distal cutting electrode tip extends at least partially within a portion of the distal jaw housing tip that defines the second height, the distal cutting electrode tip defining a fourth height within the jaw housing that is less than the second height to enable the distal cutting electrode tip to extend at least partially within the portion of the distal jaw housing tip that defines the second height.

11. The end effector assembly according to claim 10, wherein the third height of the proximal cutting electrode body is substantially constant along a length of the proximal cutting electrode body.

12. The end effector assembly according to claim 11, wherein the distal cutting electrode tip defines an angled surface extending from the proximal cutting electrode body towards the distal end of the cutting electrode, wherein the angled surface defines the taper in height of the distal cutting electrode tip.

13. The end effector assembly according to claim 10, wherein the taper in height of the distal cutting electrode tip begins within the proximal jaw housing body and extends to within the distal jaw housing tip.

14. The end effector assembly according to claim 10, wherein the taper in height of the distal cutting electrode tip begins within the distal jaw housing tip.

15. The end effector assembly according to claim 10, wherein the portion of the distal jaw housing tip that defines the second height or a height less than the second height extends along at least about 10% of a length of the second tissue contacting surface.

16. An end effector assembly of a surgical instrument, comprising: first and second jaw members including respective first and second tissue contacting surfaces, at least one of the first or second jaw members movable relative to the other of the first or second jaw members between a spaced apart position and an approximated position for grasping tissue between the first and second tissue contacting surfaces, the second jaw member including: a jaw housing including a proximal jaw housing body defining a substantially constant height and a distal jaw housing tip tapering in height from the proximal jaw housing body towards a distal end of the jaw housing; and a cutting electrode engaged within the jaw housing and extending from the second tissue contacting surface towards the first jaw member, the cutting electrode including a body extending within the proximal jaw housing body and including a distal portion extending into the distal jaw housing tip, the cutting electrode further including a plurality of retention tabs extending from the body of the cutting electrode and disposed within the proximal jaw housing body, wherein the distal portion of the cutting electrode is devoid of a retention tab.

17. The end effector assembly according to claim 16, wherein each retention tab of the plurality of retention tabs defines a through-hole to facilitate engagement of the cutting electrode within the jaw housing.

18. The end effector assembly according to claim 16, wherein the distal portion of the cutting electrode defines from about 25% to about 50% of a length of the cutting electrode.

19. The end effector assembly according to claim 16, wherein the distal jaw housing tip tapers in height from a first height of the proximal jaw housing body to a second height less than the first height, the distal jaw housing tip defining the second height along a portion of a length thereof.

20. The end effector assembly according to claim 20, wherein the body of the cutting electrode defines a third height within the jaw housing that is less than the second height, and wherein a fourth height defined by the body of the cutting electrode within the jaw housing plus a height of a retention tab of the plurality of retention tabs is greater than the second height but less than the first height.