Modular electrosurgical adaptors and multi function active shafts for use in electrosurgical instruments

[0001] The instant application claims priority to U.S. Provisional Patent Application Ser. No. 60/888,918, filed Feb. 8, 2007, and U.S. Provisional Patent Application Ser. No. 60/893,514, filed Mar. 7, 2007, the entire specifications of both of which are expressly incorporated herein by reference.

[0002] The present invention generally relates to electrosurgical instruments and more specifically to adaptors and shafts for use with electrosurgical instruments.

[0003] Recent trends in electrosurgical instrumentation, both endoscopic and open surgery, require one or more conducting channels to control and monitor current and control desired functions which are related to active elements incorporated into advanced surgical instruments.

[0004] Due to increased costs, sterilization requirements, and environmental considerations, there is a growing demand for active surgical devices, i.e., devices that have jaws for grasping, cutting, and/or dissecting, clamps, electrodes, and/or the like that may be disassembled and are adaptable. These devices may have one or more elements which are removable for cleaning or sterilization, disposal, interchangeability, or alterations.

[0005] The electrical current types required for the elements of the surgical devices could be, but are not limited to monopolar and bipolar currents in all frequencies and wave forms and DC current. Conductive channels (e.g., wires) which have extra insulation may be useful to perform various measurements within the elements of the surgical devices, such as temperature measurement, current flow measurement, measurement of conductivity, measurement of resistance, impedance, pressure, liquid and gas flow, and/or the like. In other cases, power may be required for other types of elements, such as motors, heating elements, and/or the like.

[0006] Accordingly, there exists a need for new and improved systems and methods for providing or constructing electrosurgical devices which are adaptable and/or active that overcome at least one of the disadvantages of the prior art.

[0007] The present invention describes a system and a method to provide or construct surgical devices (e.g., electrosurgical devices) which are adaptable and/or active. The unique features of these devices are in the electrosurgical adaptors that allow attachment and detachment. In addition, sterilization of the elements and within compound shafts of the surgical devices may also be performed. Further, contacts and insulation arrangements within the adaptors, and related compound shafts, enable essential mechanical movements while being able to include a plurality of wire conductors. These wires convey currents and signals to and from the elements (e.g., jaws, tongs, electrodes, and/or the like). The specific designs of handles, adaptors, and compound shafts within the electrosurgical instruments permit unlimited rotation while allowing attachment/detachment of the elements from the electrosurgical instruments.

[0008] More specifically, the present invention also discloses the necessary details to construct attachable/detachable, multi function, active surgical devices. The devices may be attached or detached to a surgical handle which provides a plurality of electrical and mechanical connections. The mechanical and electrical connections may activate and connect the devices via electrosurgical adaptors, contacts, connectors, wires, cables or shafts that are within the detachable surgical devices. The surgical devices could perform a variety of mechanical movements (e.g., grasping, dissecting, and/or shearing), be rotated beyond 360 degrees, and perform electro-cautery, electro-dissecting, coagulation, or homeostasis functions on a variety of tissue types. Further, these attachable/detachable devices may be equipped with extra electrical contacts and wires, which convey extra power, control and measurement to and from the elements of the electrosurgical devices, through the handle, via a generator. However, any other desired and related input or control unit may also be provided for use with the detachable devices.

[0009] Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposed of illustration only and are not intended to limit the scope of the invention.

[0051] The same reference numerals refer to the same parts throughout the various Figures.

[0052] The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, or uses. Referring to the Figures generally, wherein like numerals indicate like parts throughout the several views, and specifically to FIG. 1, an electrosurgical forceps is shown generally 1.

[0053] The forceps 1 include a handle body 4, a surgical device 2, and a pair of handles 9, 10. The surgical device 2 is removably disposed within the handle body 4. The handles 9, 10 are pivotally attached to the handle body for articulating jaws 47, 48 on the surgical device 2, or grasping the forceps 1.

[0054] The surgical device 2 includes an adaptor body 3, preferably from non-conductive material such as polymer or ceramic, which is attached to the handle body 4 via a locking piece 5, as shown in FIG. 1-2. The adaptor body 3 defines a hollow passage 6. The hollow passage 6 allows reciprocal movements of compound shaft assembly 7 within a tubular element 8. Reciprocal movements are caused by closing or opening the handles 9 and 10 with respect to one another. When the handles 9 and 10 are closed, a stem assembly 11 is pulled proximally via links 12 and 13 and the retreat of a collet 14, which pulls an end 27 of compound shaft assembly 7 proximally.

[0055] FIG. 1-2 is a cross-section view, taken through the handle body 4 and the adaptor body 3, which shows a power plug assembly 15. The electrosurgical adaptor body 3 includes two contact rings 16 and spring contacts 17. Insulated wires 18, 19, 20, respectively, that are connected with axial rings 21, 23, 22 respectively, carry current from the power plug assembly 15 to a collet housing 24 and body spring contacts 25, 26.

[0056] Spring contacts 25, 26, and the collet housing 14, carry current to the contact rings 16 and the collet 14, respectively. Spring contacts 17, disposed within the adaptor body 3, carry currents to shaft conducting connectors and an end 27 of the compound shaft 7.

[0057] Torque is applied to the tubular element 8 or a rotation knob 28, shown in FIG. 2-1, which allows the surgical device 2 to rotate within handle body 4 while retaining continuous contacts from the power plug assembly 15 through the wires, housing, contacts and/or conductors. Therefore, independent currents may be conveyed via the incorporation of extra wires 33, 34 for other functions as stated above (e.g., see FIG. 2-3).

[0058] FIG. 2-2 shows a monopolar activating shaft 29, attached to an end 27 of the compound shaft assembly 7. The activating shaft 29 causes opening and closing of jaws 30, 31, via links 32, which act in concert with relative positions of the handles 9, 10 and a mechanical train, i.e., links 12, 13, stem assembly 11, collet 14, and/or the like.

[0059] FIGS. 3-1, 3-2, and 3-3 show details of another example, in this case, a bipolar detachable device with two extra wire channels. Additionally, the handle body may be constructed to allow an insulated passage for a plurality of the conductive wires.

[0060] In this specific case, the adaptor body 35, carrying three contact rings 37, 38, 39, is housing a compound shaft 45 as shown. The shaft end 40 receives a positive current and is attached to conductive, insulated wire 41, driving link 46 and causing movement of jaw 47, rotated on insulated pin 49. Negative wire 42 similarly drives jaw 48 via link 50. Thus, while retaining insulation throughout, except when contacts are required for continuity, jaws 47, 48 will be charged in a bipolar fashion. Extra wires 43 and 44 allow other desired functions, as mentioned earlier, to be performed.

[0061] FIGS. 4-1, 4-2, 4-3, and 4-4 show another embodiment of a monopolar electrosurgical attachable device 51, where a compound shaft end 52 is connected to a positive electrical source via a handle body. Four contact rings 53 allow for the connection and/or application of other desired functions.

[0062] FIGS. 5-1 and 5-2 show a bipolar compound shaft 110 with two extra wires 58, 59. When an end 54 of the compound shaft 110 is securely attached to a non-conducting shaft connector 55, the whole shaft assembly and other wires, 57, 58, 59 are advanced within the adaptor body. The wires 56 and 57 activate and charge the jaws 47, 48, while the wires 58 and 59 are available for other tasks. Note that shaft end 54 and non-conductive and conductive connectors 55, 60, respectively, are attached rigidly.

[0063] FIGS. 5-5 and 5-6 show a construction of a monopolar compound shaft 110.

[0064] FIGS. 6-1 through 6-7 show a non-conductive adaptor body 61, defining a circumferential locking groove 62 and a contact ring groove 63. The adaptor body 61 defines a hole 66 within the contact ring groove 63. A spring contact 65, as illustrated in FIG. 6-3, is seated within the hole 66. A contact ring 64 (e.g., see FIG. 6-4) contacts and compresses the spring contact 65 within the hole 66 to conduct current to or from the compound shaft 100, 110, within a passage, defined in the adaptor body 61.

[0065] FIG. 7-1 shows a cross-sectional side view through an alternative embodiment of the modular electrosurgical forceps 300. The forceps 300 include a detachable endoscopic bipolar surgical device 302. The surgical device 302 of this embodiment is rotatable, while maintaining electrical contact. The surgical device 302 includes an adaptor body 303, preferably formed from non-conductive material such as polymer or ceramic, which is attached to a handle body 304 via a locking piece 305, as shown in FIG. 7-2. The adaptor body 303 defines a hollow passage 306. The hollow passage 306 allows reciprocal movements of a compound shaft assembly 307 within a tubular element 308. The reciprocal movements result from closing and/or opening the handles 9, 10. In this embodiment, closure of the handles 9, 10 causes the stem assembly 311 to be pulled proximally via links 312 and 313. As the links 312, 313 pull the stem assembly 311 proximally, the stem assembly 311 pulls a collet 314 proximally. The collet 314, which grasps the compound shaft 307, pulls the compound shaft 307 proximally.

[0066] FIG. 7-2 shows an enlarged cross-sectional view taken through the handle body 304 and the adaptor body 303. Insulated wiring 202, 203 connect to spring contacts 204, 205, respectively. The spring contacts 204, 205 touch contact rings 316, disposed on the compound shaft 307. Therefore, the adaptor body 303 of the forceps 300 includes two contact rings 316 and spring contacts 317. Insulated wire 201 connects to a collet contact 206. The collet contact 206 extends into a groove 323 defined by a collet housing 324. The collet housing 324 is disposed within the hollow passage 306. The collet housing 324 is formed from a metallic, or other conductive material. The contact rings 207 are connected to wires 208, 209. A cable end 210, which extends from the compound shaft 307, is conductive and conveys current to wire 211.

[0067] Referring to FIG. 8-4, a typical contact assembly 212 is shown. The assembly 212 includes a contact ring 207 which is connected to an insulated wire 208. The insulated wire 208 includes an end which is exposed and soldered, crimped, welded, or otherwise attached to the contact ring 207.

[0068] Referring to FIGS. 8-1 and 8-2, the compound shaft assembly 307 is shown. The compound shaft assembly 307 includes a cable end 210 which is connected to a non-conductive core 217. Two contact rings 207 are placed in recesses 218 which are defined in the non-conductive core 217, as shown generally in FIG. 2-3. Wires 215, 216 are disposed within grooves 219, defined along the non-conductive core 217. FIG. 8-3 shows an exploded isometric view of the compound shaft assembly 307. A wire 216 is attached to the contact ring 207 and extends underneath the contact ring 207, located distally from the contact ring 207. Additionally, a wire 215 is attached to the contact ring 207.

[0069] An adaptor 213 is normally snapped, or otherwise attached, at a distal end of the compound shaft assembly 307 to secure wires 215, 216 which are bent, as shown in FIG. 8-3. This reduces flexure of the bent portions 220.

[0070] FIGS. 9-1a, 9-1b, and 9-1c show various views of the non-conductive core 217. FIG. 9-2 shows another embodiment of a non-conductive core 217 which defines four recesses 218 and a through-hole. The additional two recesses allow the non-conductive core 217 to be assembled for up to five live wires.

[0071] FIGS. 9-3a-d shows views of the adaptor 213, preferably from non-conductive, elastic material. FIG. 9-4 shows a typical contact ring 207 defining a slot 214. The contact ring 207 is preferably formed from elastic, conductive material, which allows it to be resilient such that it expands over the non-conducting core 217 and snaps back to its original size while resting in the recess 218.

[0072] While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes can be made and equivalents can be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.