JP7725792B2 - Electrosurgical system with integrated and external power source - Google Patents

Description

CROSS-REFERENCE TO RELATED APPLICATIONS
This non-provisional application claims the benefit under 35 U.S.C. § 119(e) of U.S. Provisional Application No. 62/955,299, filed December 30, 2019, entitled "DEVICES AND SYSTEMS FOR ELECTROSURGERY," the entire disclosure of which is incorporated herein by reference.

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

In various embodiments, a surgical system is disclosed that includes 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 battery in electrical communication with the generator. The housing includes an electric motor. The shaft defines a longitudinal shaft axis. The end effector is operatively 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 transverse to the longitudinal shaft axis. The generator cannot directly provide sufficient power to the electric motor to operate it. The internal battery is configured to provide power to the electric motor. The internal battery is rechargeable by the generator to a threshold value at a charge rate that depends on the charge level of the internal battery. The charge rate is independent of charge consumption by the surgical instrument.

In various embodiments, a surgical system is disclosed that includes 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 battery. 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 battery is in electrical communication with the power source. The internal battery is configured to provide power to the electric motor. The internal battery is rechargeable by the power source to a threshold value at a charge rate that depends on the charge level of the internal battery. The internal battery is rechargeable by the power source while the electric motor drives the end effector to perform an end effector function.

In various embodiments, a surgical instrument is disclosed that includes 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 battery connected to the electric motor. The electric motor is configured to cause the end effector to perform an end effector function. The power supply assembly is connectable to two separate power sources. The power supply assembly is configured to separately receive first and second power sources from the power sources. The power supply assembly is configured to transmit the second power source to the internal battery. The power supply assembly is configured to transmit the first power source to the electric motor and the internal battery. The power supply assembly is configured such that the electric motor is simultaneously powered by the internal battery and the first power source.

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, can best be understood by reference to the following description taken in conjunction with the accompanying drawings.
1 illustrates an example of a generator for use with a surgical instrument, according to at least one aspect of the present disclosure. 1 illustrates one form of a surgical system including a generator and an electrosurgical instrument usable with the generator, in accordance with at least one aspect of the present disclosure. 1 shows a schematic diagram of a surgical instrument or tool according to at least one aspect of the present disclosure. FIG. 1 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. 5 is a plan view of one of the jaws of the end effector of FIG. 4; FIG. 5 is a side elevational view of another one of the jaws of the end effector of FIG. 4 . FIG. 1 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. 9 is an exploded perspective view of one of the jaws of the end effector of FIG. 8 . FIG. 10 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. 10 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. 10 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. 10 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. 10 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. 10 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. 10 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. 10 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. 10 is a graph illustrating a power scheme for coagulating and cutting a tissue treatment area in a treatment cycle applied by an end effector in accordance with at least one aspect of the present disclosure. FIG. 1 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. 21 is a partial side elevational view of the flexible wiring assembly of FIG. 20 in an extended configuration. FIG. 1 is a perspective view of a wiring harness and inductive sensor for use with a surgical instrument according to at least one aspect of the present disclosure. FIG. 1 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. 1 is a perspective view of a surgical instrument including a manual toggle member, according to at least one aspect of the present disclosure. FIG. 27 is a cross-sectional end view of the manual toggle of FIG. 26 showing the manual toggle member in a rotated position. FIG. 28 is a cross-sectional end view of the manual toggle member of FIG. 27 in a center position. FIG. 27 is a schematic diagram of the surgical instrument of FIG. 26; FIG. 27 is a perspective exploded view of the surgical instrument of FIG. 26 showing the manual toggle member and elongated shaft; FIG. 31 is a plan view of the elongated shaft of FIG. 30 showing the position of the elongated shaft when the manual rocker member is in a center position. FIG. 31 is a plan view of the elongated shaft of FIG. 30 showing the position of the elongated shaft when the manual toggle member is rotated counterclockwise. FIG. 31 is a plan view of the elongated shaft of FIG. 30 showing the position of the elongated shaft when the manual toggle member is rotated clockwise. FIG. 1 is a schematic diagram of a surgical system according to at least one aspect of the present disclosure. 35 is a graph of the battery recharge rate, battery charge rate, power consumption, and motor speed over time for the surgical system of FIG. 34. FIG. 1 is a side view of a surgical system including a surgical instrument, a monopolar generator, and a bipolar generator, in accordance with at least one aspect of the present disclosure. FIG. 10 is a schematic diagram of battery charge rate and motor torque for multiple surgical tool systems over time in accordance with at least one aspect of the present disclosure;

The applicant of the present application owns the following US patent applications, filed on even date herewith, each of which is incorporated herein by reference in its entirety:
Attorney Docket No. END9234USNP1/190717-1M, Title of Invention: "METHOD FOR AN ELECTROSURGICAL PROCEDURE"
- Attorney Docket No. END9234USNP2/190717-2, Title of Invention: "ARTICULATABLE SURGICAL INSTRUMENT";
- Attorney Docket No. END9234USNP3/190717-3, Title of Invention: "SURGICAL INSTRUMENT WITH JAW ALIGNMENT FEATURES";
- Attorney Docket No. END9234USNP4/190717-4, Title of Invention: "SURGICAL INSTRUMENT WITH ROTATABLE AND ARTICULATABLE SURGICAL END EFFECTOR";
Attorney Docket No. END9234USNP5/190717-5, Title of Invention: "ELECTROSURGICAL INSTRUMENT WITH ASYNCHRONOUS ENERGIZING ELECTRODES";
Attorney Docket No. END9234USNP6/190717-6, Title of Invention: "ELECTROSURGICAL INSTRUMENT WITH ELECTRODES BIASING SUPPORT"
Attorney Docket No. END9234USNP7/190717-7, Title of Invention: "ELECTROSURGICAL INSTRUMENT WITH FLEXIBLE WIRING ASSEMBLIES";
- Attorney Docket No. END9234USNP8/190717-8, Title of Invention: "ELECTROSURGICAL INSTRUMENT WITH VARIABLE CONTROL MECHANISMS";
Attorney Docket No. END9234USNP10/190717-10, Title of Invention: "ELECTROSURGICAL INSTRUMENTS WITH ELECTRODES HAVING ENERGY FOCUSING FEATURES";
Attorney Docket No. END9234USNP11/190717-11, Title of Invention: "ELECTROSURGICAL INSTRUMENTS WITH ELECTRODES HAVING VARIABLE ENERGY DENSITIES";
Attorney Docket No. END9234USNP12/190717-12, Title of Invention: "ELECTROSURGICAL INSTRUMENT WITH MONOPOLAR AND BIPOLAR ENERGY CAPABILITIES";
Attorney Docket No. END9234USNP13/190717-13, Title of Invention: "ELECTROSURGICAL END EFFECTORS WITH THERMALLY INSULATIVE AND THERMALLY CONDUCTIVE PORTIONS";
Attorney Docket No. END9234USNP14/190717-14, Title of Invention: "ELECTROSURGICAL INSTRUMENT WITH ELECTRODES OPERABLE IN BIPOLAR AND MONOPOLAR MODES"
Attorney Docket No. END9234USNP15/190717-15, Title of Invention: "ELECTROSURGICAL INSTRUMENT FOR DELIVERING BLENDED ENERGY MODALITIES TO TISSUE";
Attorney Docket No. END9234USNP16/190717-16, Title of Invention: "CONTROL PROGRAM ADAPTATION BASED ON DEVICE STATUS AND USER INPUT"
Attorney Docket No. END9234USNP17/190717-17, entitled "CONTROL PROGRAM FOR MODULAR COMBINATION ENERGY DEVICE", and Attorney Docket No. END9234USNP18/190717-18, entitled "SURGICAL SYSTEM COMMUNICATION PATHWAYS".

The applicant of the present application owns the following U.S. provisional patent applications, filed December 30, 2019, the disclosures of each of which are incorporated herein by reference in their entirety:
- U.S. Provisional Patent Application No. 62/955,294, entitled "USER INTERFACE FOR SURGICAL INSTRUMENT WITH COMBINATION ENERGY MODALITY END-EFFECTOR";
US Provisional Patent Application No. 62/955,292, entitled "COMBINATION ENERGY MODALITY END-EFFECTOR," and US Provisional Patent Application No. 62/955,306, entitled "SURGICAL INSTRUMENT SYSTEMS."

The applicant of the present application owns the following US patent applications, the disclosures of each of which are incorporated herein by reference in their entirety:
U.S. Patent Application No. 16/209,395, entitled "METHOD OF HUB COMMUNICATION" (now U.S. Patent Application Publication No. 2019/0201136);
U.S. Patent Application 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 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 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 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 No. 16/209,427, entitled "METHOD OF USING REINFORCED FLEXIBLE CIRCUITS WITH MULTIPLE SENSORS TO OPTIMIZES PERFORMANCE OF RADIO FREQUENCY DEVICES" (now U.S. Patent Application Publication No. 2019/0208641);
U.S. Patent Application No. 16/209,433, entitled "METHOD OF SENSING PARTICULATE FROM SMOKE EVACUATED FROM A PATIENT, ADJUSTING THE PUMP SPEED BASED ON THE SENSED INFORMATION, AND COMMUNICATING THE FUNCTIONAL PARAMETERS OF THE SYSTEM TO THE HUB" (now U.S. Patent Application Publication No. 2019/0201594);
U.S. Patent Application No. 16/209,447, entitled "METHOD FOR SMOKE EVACUATION FOR SURGICAL HUB" (now U.S. Patent Application Publication No. 2019/0201045);
U.S. Patent Application No. 16/209,453, entitled "METHOD FOR CONTROLLING SMART ENERGY DEVICES" (now U.S. Patent Application Publication No. 2019/0201046);
U.S. Patent Application No. 16/209,458, entitled "METHOD FOR SMART ENERGY DEVICE INFRASTRUCTURE" (now U.S. Patent Application Publication No. 2019/0201047);
U.S. Patent Application No. 16/209,465, entitled "METHOD FOR ADAPTIVE CONTROL SCHEMES FOR SURGICAL NETWORK CONTROL AND INTERACTION" (now U.S. Patent Application Publication No. 2019/0206563);
U.S. Patent Application No. 16/209,478, entitled "METHOD FOR SITUATIONAL AWARENESS FOR SURGICAL NETWORK OR SURGICAL NETWORK CONNECTED DEVICE CAPABLE OF ADJUSTING FUNCTION BASED ON A SENSED SITUATION OR USAGE" (now U.S. Patent Application Publication No. 2019/0104919);
U.S. Patent Application 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 No. 16/209,491, entitled "METHOD FOR CIRCULAR STAPLER CONTROL ALGORITHM ADJUSTMENT BASED ON SITUATIONAL AWARENESS" (now U.S. Patent Application Publication No. 2019/0200998);
- U.S. Patent Application No. 16/562,123, entitled "METHOD FOR CONSTRUCTING AND USING A MODULAR SURGICAL ENERGY SYSTEM WITH MULTIPLE DEVICES";
- U.S. Patent Application No. 16/562,135, entitled "METHOD FOR CONTROLLING AN ENERGY MODULE OUTPUT";
U.S. Patent Application No. 16/562,144, entitled "METHOD FOR CONTROLLING A MODULAR ENERGY SYSTEM USER INTERFACE," and U.S. Patent Application No. 16/562,125, entitled "METHOD FOR COMMUNICATING BETWEEN MODULES AND DEVICES IN A MODULAR SURGICAL SYSTEM."

Before describing various aspects of the surgical visualization platform in detail, it should be noted that the illustrative embodiments are not limited in application or use to the details of construction and arrangement of parts illustrated in the accompanying drawings and specification. The illustrative embodiments may be embodied in or incorporated into other aspects, variations, and modifications, and may be practiced or carried out in various ways. Furthermore, unless otherwise specified, the terms and phrases used herein have been chosen for the convenience of the reader for the purpose of describing the illustrative embodiments, and not for the purpose of limiting them. Furthermore, it should be understood that one or more of the aspects, aspect expressions, and/or examples described below can be combined with any one or more of the other aspects, aspect expressions, and/or examples described below.

Various aspects are directed to electrosurgical systems that include electrosurgical instruments powered by a generator to effect dissection, cutting, and/or coagulation of tissue during surgical procedures. The electrosurgical instruments may be configured for use in open surgical procedures, but also have applications in other types of surgery, such as laparoscopic, endoscopic, and robotic-assisted procedures.

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

FIG. 1 shows an example of a generator 900 configured to deliver multiple energy modalities to a surgical instrument. The generator 900 provides RF and/or ultrasonic signals for delivering energy to the surgical instrument. The generator 900 includes at least one generator output capable of delivering multiple energy modalities (e.g., ultrasound, bipolar or monopolar RF, irreversible and/or reversible electroporation, and/or microwave energy, among others) through a single port, which can be delivered individually or simultaneously to an 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 generate various signal waveforms based on information stored in a memory coupled to the processor 902, not shown for clarity of disclosure. Digital information related to the waveforms is provided to the waveform generator 904, which includes one or more DAC circuits for converting the digital input to an analog output. The analog output is provided to an amplifier 906 for signal conditioning and amplification. The conditioned and amplified output of amplifier 906 is coupled to a power transformer 908. The signal is coupled across power transformer 908 to a secondary on the patient-isolated side. A first signal of a first energy modality is provided between terminals labeled ENERGY ₁ and RETURN on the surgical instrument. A second signal of a second energy modality is coupled across capacitor 910 and provided between terminals labeled ENERGY ₂ and RETURN on the surgical instrument. It will be understood that more than two energy modalities may be output, and thus the subscript "n" may be used to indicate that up to n ENERGY _n terminals may be provided, where n is a positive integer greater than 1. It will also be understood that up to "n" return paths (RETURN _n ) may be provided without departing from the scope of this disclosure.

A first voltage sense circuit 912 is coupled across the terminals labeled ENERGY ₁ and RETURN PATH and measures the output voltage therebetween. A second voltage sense circuit 924 is coupled across the terminals labeled ENERGY ₂ and RETURN PATH and measures the output voltage therebetween. A current sense circuit 914 is disposed in series with the RETURN section of the secondary side of the shown power transformer 908 to measure the output current of either energy modality. If different return paths are provided for each energy modality, a separate current sense circuit must be provided in each return section. The outputs of the first voltage sense circuit 912 and the second voltage sense circuit 924 are provided to corresponding isolation transformers 928, 922, and the output of the current sense circuit 914 is provided to another isolation transformer 916. The outputs of the isolation transformers 916, 928, 922 on the primary side (non-patient-isolated 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 calculations. Feedback information of the output voltage and output current can be used to calculate parameters such as output impedance to adjust the output voltage and current provided to the surgical instrument. Input/output communication between the processor 902 and the patient-isolated circuitry is provided via an interface circuit 920. Sensors may also be in electrical communication with the processor 902 via the interface circuit 920.

In one aspect, impedance may be determined by processor 902 by dividing the output of either a first voltage sense circuit 912 coupled across the terminals labeled ENERGY ₁ /RETURN or a second voltage sense circuit 924 coupled across the terminals labeled ENERGY ₂ /RETURN by the output of a current sense circuit 914 placed in series with the RETURN section of the secondary of power transformer 908. The outputs of first voltage sense circuit 912 and second voltage sense circuit 924 are provided to separate isolation transformers 928, 922, and the output of current sense circuit 914 is provided to another isolation transformer 916. Digitized voltage and current sense measurements from ADC circuit 926 are provided to processor 902 to calculate impedance. As an example, first energy modality ENERGY ₁ may be RF monopolar energy and second energy modality ENERGY ₂ may be RF bipolar energy. Yet, 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 illustrated in Figure 1 shows that a single return path (RETURN) may be provided to two or more energy modalities, in other aspects, multiple return paths RETURN _n may be provided to each energy modality ENERGY _n .

As shown in FIG. 1 , a generator 900 with at least one output port can include a power transformer 908 with a single output and multiple taps to provide power to an 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, among others, depending on the type of tissue treatment being performed. For example, the generator 900 can deliver high-voltage, low-current energy to drive an ultrasonic transducer, low-voltage, high-current energy to drive an RF electrode to seal tissue, or energy having a coagulation waveform for spot coagulation using either monopolar or bipolar RF electrosurgical electrodes. The output waveform from the generator 900 can be directed, switched, or filtered to provide a frequency to the end effector of the surgical instrument. In one example, the connection of an RF bipolar electrode to the output of the generator 900 would preferably be located between the output labeled ENERGY ₂ and RETURN. For unipolar outputs, it may be preferable to connect the active electrode (eg, pencil or other probe) to the ENERGY ₂ output and a suitable return pad to the RETURN output.

Additional details are disclosed in U.S. Patent Application Publication No. 2017/0086914, published March 30, 2017, entitled "TECHNIQUES FOR OPERATING GENERATOR FOR DIGITALLY GENERATING ELECTRICAL SIGNAL WAVEFORMS AND SURGICAL INSTRUMENTS," which is incorporated herein by reference in its entirety.

2 illustrates one form of a surgical system 1000 including a generator 1100 and various surgical instruments 1104, 1106, 1108 usable therewith, where the surgical instrument 1104 is an ultrasonic surgical instrument, the surgical instrument 1106 is an RF electrosurgical instrument, and the multifunction surgical instrument 1108 is a combination ultrasonic/RF electrosurgical instrument. The generator 1100 is configurable for use with a variety of surgical instruments. According to various forms, the generator 1100 may be configurable for use with a variety of different types of surgical devices, including, for example, the ultrasonic surgical instrument 1104, the RF electrosurgical instrument 1106, and the multifunction surgical instrument 1108 that integrates RF and ultrasonic energy delivered simultaneously from the generator 1100. While the generator 1100 is shown separate from the surgical instruments 1104, 1106, and 1108 in the configuration of FIG. 2, in one configuration the generator 1100 may be integrally formed with any of the surgical instruments 1104, 1106, and 1108 to form an integrated surgical system. The generator 1100 includes an input device 1110 located on a front panel of the console of the generator 1100. The input device 1110 may include any suitable device for generating signals suitable for programming the operation of the generator 1100. The generator 1100 may be configured for wired or wireless communication.

The generator 1100 is configured to drive multiple surgical instruments 1104, 1106, and 1108. The first surgical instrument is an ultrasonic surgical instrument 1104, which 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 acoustically coupled to the ultrasonic transducer 1120 and a clamp arm 1140. The handpiece 1105 includes a trigger 1143 for operating the clamp arm 1140 and a combination of toggle buttons 1137, 1134b, and 1134c for energizing and driving the ultrasonic blade 1128 or other functions. The toggle buttons 1137, 1134b, and 1134c can be configured to energize the ultrasonic transducer 1120 using the generator 1100.

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 clamp arms 1145, 1142b and return through an electrical conductor portion of the shaft 1127. The electrodes are coupled to and energized by a bipolar energy source within the generator 1100. The handpiece 1107 includes a trigger 1145 for operating the clamp 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 can also be used with a return pad to deliver monopolar energy to tissue.

The generator 1100 is also configured to drive a multifunction surgical instrument 1108. The multifunction surgical instrument 1108 includes a handpiece 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 trigger 1147 that operates the clamp arm 1146 and a combination of toggle buttons 11310, 1137b, and 1137c for energizing and driving the ultrasonic blade 1149 or other functions. Toggle buttons 11310, 1137b, 1137c can be configured to energize the ultrasonic transducer 1120 using the generator 1100 and also to energize the ultrasonic blade 1149 using a bipolar energy source housed within the generator 1100. Monopolar energy can be delivered to tissue in combination with or separate from bipolar energy.

The generator 1100 is configurable for use with a variety of surgical instruments. According to various configurations, 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 multifunction surgical instrument 1108 that integrates RF and ultrasonic energy delivered simultaneously from the generator 1100. In the configuration of FIG. 2, the generator 1100 is shown separate from the surgical instruments 1104, 1106, and 1108; however, in other configurations, the generator 1100 may be integrally formed with any one of the surgical instruments 1104, 1106, and 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. The input device 1110 may include any suitable device that generates signals suitable for programming the operation of the generator 1100. The generator 1100 may also include one or more output devices 1112. Further aspects of generators for digitally generating electrical signal waveforms and surgical instruments are described in U.S. Patent Application Publication No. 2017-0086914 (A1), the entirety of which is incorporated herein by reference.

FIG. 3 shows a schematic diagram of a surgical instrument or tool 600 including multiple motor assemblies that can be activated to perform various functions. In the illustrated example, a closure motor assembly 610 is operable to transition the end effector between an open configuration and a closed configuration, and an articulation motor assembly 620 is operable to articulate the end effector relative to the shaft assembly. In certain examples, the multiple motor assemblies can be individually activated to produce firing, closing, and/or articulation motions in the end effector. The firing, closing, and/or articulation motions can be transmitted to the end effector via the shaft assembly, for example.

In certain examples, the closure motor assembly 610 includes a closure motor. The closure 603 may be 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, specifically to displace the closure member to close and transition the end effector to a closed configuration. The closure motion may, for example, transition the end effector from an open configuration to a closed configuration to capture tissue. The end effector may be transitioned to the open position by reversing the direction of the motor.

In certain examples, the articulation motor assembly 620 includes an articulation motor operably coupled to an articulation drive assembly 622, which can be configured to transmit articulation generated by the motor to the end effector. In certain examples, the articulation can, for example, cause the end effector to articulate relative to the shaft.

One or more of the motors of the surgical instrument 600 may be equipped with a torque sensor to measure the output torque on the motor's shaft. The force on the end effector may be sensed in any conventional manner, such as by a force sensor outside the jaws or by a torque sensor on the motor that actuates the jaws.

In various examples, the motor assemblies 610, 620 include one or more motor drivers, which may include one or more H-bridge FETs. The motor drivers may modulate the power delivered to the motors from the power supply 630 based on inputs from, for example, a microcontroller 640 ("controller") in the control circuit 601. In certain examples, the microcontroller 640 may be used to measure, for example, the current draw by the motors.

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

In certain examples, the power supply 630 may be used to power, for example, the microcontroller 640. In certain examples, the power supply 630 may include a battery (or "battery pack" or "power pack"), such as, for example, a lithium-ion battery. In certain examples, the battery pack may be configured to be releasably attached to the handle to power the surgical instrument 600. Multiple battery cells connected in series may be used as the power supply 630. In certain examples, the power supply 630 may be, for example, replaceable and/or rechargeable.

In various examples, processor 642 may control motor drivers to control the position, direction of rotation, and/or speed of the motors of assemblies 610, 620. In certain examples, processor 642 may signal the motor drivers to stop and/or disable the motors. As used herein, the term "processor" should be understood to include any suitable microprocessor, microcontroller, or other basic computing device that integrates the functionality of a computer's central processing unit (CPU) on a single integrated circuit or up to several integrated circuits. Processor 642 is a general-purpose programmable device that accepts digital data as input, processes that data according to instructions stored in memory, and provides the results as output. Because it has internal memory, it is an example of sequential digital logic. The processor operates on numbers and symbols represented in the binary system.

In one example, 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 a particular example, microcontroller 620 may be, for example, an LM 4F230H5QR available from Texas Instruments. In at least one embodiment, the Texas Instruments LM4F230H5QR is an ARM Cortex-M4F processor core that includes, among other features readily available on the product datasheet, on-chip memory of 256 KB of single-cycle flash memory or other non-volatile memory up to 40 MHz, a prefetch buffer to improve performance beyond 40 MHz, 32 KB of single-cycle SRAM, internal ROM loaded with StellarisWare® software, 2 KB of EEPROM, one or more PWM modules, one or more QEI analogs, and one or more 12-bit ADCs with 12 analog input channels. Other microcontrollers may be readily substituted for use with surgical instrument 600. Accordingly, the present disclosure should not be limited in this context.

In certain examples, memory 644 may include program instructions that control each of the motors of surgical instrument 600. For example, memory 644 may include program instructions for controlling a closure motor and an articulation motor. Such program instructions may cause processor 642 to control the closure and articulation functions according to input from an algorithm or control program of surgical instrument 600.

In certain examples, one or more mechanisms and/or sensors, such as, for example, sensor 645, can be used to alert processor 642 to the program instructions to use in a particular setting. For example, sensor 645 can alert processor 642 to use program instructions associated with closing and articulating the end effector. In certain examples, sensor 645 can include, for example, a position sensor that can be used to sense the position of a closure actuator. Thus, processor 642 can activate the motor of closure drive assembly 620 using program instructions associated with closing the end effector when processor 642 receives a signal from sensor 630 indicating actuation of the closure actuator.

In some examples, the motors may be brushless DC electric motors, and each motor drive signal may include a PWM signal 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 generate the motor drive signals directly.

During various laparoscopic procedures, it is common practice to insert the surgical end effector portion of a surgical instrument through a trocar placed in the patient's abdominal wall to access a surgical site located within the patient's abdomen. In its simplest form, a trocar is a pen-shaped instrument with a sharp triangular tip on one end that is typically used within a hollow tube known as a cannula or sleeve to create an opening in the body through which a surgical end effector can be introduced. Such a configuration creates an access port within the body cavity through which the surgical end effector can be inserted. The inner diameter of the trocar's cannula 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 specific type of surgical procedure being performed, once a surgical end effector is inserted into a patient through a trocar cannula, it is often necessary to move the surgical end effector relative to a shaft assembly positioned within the trocar cannula in order to properly position the surgical end effector relative to the tissue or organ being treated. This movement or positioning of the surgical end effector relative to the portion of the shaft that remains within the trocar cannula is often referred to as "articulation" of the surgical end effector. To facilitate such articulation of the surgical end effector, various articulation joints have been developed for attaching the surgical end effector to its associated shaft. As anticipated in many surgical procedures, it is desirable to use a surgical end effector that has as large a range of articulation as possible.

Due to size constraints imposed by the size of the trocar cannula, the components of the articulation joint must be sized to be freely insertable through the trocar cannula. These size constraints also limit the size and configuration of the various drive members and components that operably interface with motors and/or other control systems supported within the housing, which may be handheld or comprise part of a larger automated system. Often, these drive members must operably pass through the articulation joint to be operably coupled to or operably interfaced with the surgical end effector. For example, one such drive member is commonly used to impart an articulation control motion to the surgical end effector. During use, the articulation drive member is inactivated to position the surgical end effector in a non-articulated position to facilitate insertion of the surgical end effector through the trocar, and can then be activated to articulate the surgical end effector to a desired position once the surgical end effector has entered the patient.

The aforementioned size constraints therefore pose many challenges in developing an articulation system that can achieve the desired range of articulation and also accommodate the various different drive systems required to operate the various features of a surgical end effector. Furthermore, once the surgical end effector is positioned in a desired articulation position, the articulation system and articulation joint must be able to hold the surgical end effector in that position during actuation of the end effector and performance of the surgical procedure. Such articulation joint configuration must also be able to withstand the external forces experienced by the end effector during use.

Figures 4-7 show an electrosurgical instrument 30100 comprising a first jaw 30110, a second jaw 30120, and a monopolar wedge-shaped electrode 30130. The first jaw 30110 and the second jaw 30120 are movable between open and closed positions and are configured to grasp tissue T therebetween. The first jaw 30110 and the second jaw 30120 each comprise an electrode electrically coupled to a generator. Exemplary suitable generators 900, 1100 are described above in connection with Figures 1 and 2. The generator is configured to power and cause the electrodes of the first and second jaws 30110, 30120 to cooperatively deliver bipolar energy to seal, coagulate, and/or cauterize tissue in a bipolar tissue treatment cycle.

During use, the first jaw 30110 and the second jaw 30120 may be deflected away from each other at their distal ends when tissue T is grasped therebetween. As tissue T is grasped, the tissue T exerts a force on the first jaw 30110 and the second jaw 30120, causing the jaws to be deflected away from each other. More specifically, when tissue T is grasped between the first jaw 30110 and the second jaw 30120, a gap B between the first jaw 30110 and the second jaw 30120 toward the distal ends of the jaws may be larger than a gap A between the first jaw 30110 and the second jaw 30120 toward the proximal ends of the jaws.

In addition to the above, the end effector 30100 of the electrosurgical instrument 30100 further comprises a monopolar wedge electrode 30130 electrically connected to a generator (e.g., generator 900, 1100) and configured to cut tissue T positioned between the first jaw 30110 and the second jaw 30120 when energized by the generator. In the illustrated embodiment, the monopolar wedge electrode 30130 is fixed to the second jaw 30120, although other embodiments are envisioned in which the monopolar wedge electrode 30130 is fixed 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 comprises 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 when tissue is grasped therebetween. In at least one embodiment, the monopolar wedge electrode 30130 includes a flexible flex circuit board 30132. The flexible flex circuit board 30132 is configured to bend and/or flex longitudinally to offset deflection of the first jaw 30110 and the second jaw 30120 when tissue is grasped therebetween.

In various examples, the monopolar wedge-shaped electrode 30130 includes a conductive member 30134 centrally disposed along the length of the flexible flex circuit board 30132. In the illustrated example, the conductive member 30134 is disposed on the flexible flex circuit board 30132, where at least a portion of the conductive member 30134 is exposed through the top surface of the flexible flex circuit board 30132. In certain examples, portions of the conductive member 30134 are exposed, while other portions are covered by the flexible flex circuit board 30132.

In examples where the jaws 30110, 30120 have a curved shape, the monopolar wedge electrode 30130 extends longitudinally with a similar curved profile. Furthermore, the monopolar wedge electrode 30130 gradually changes in width from larger to smaller as it extends longitudinally. Thus, the first width of the monopolar wedge electrode 30130 near its proximal end is larger than the second width near its distal end, as shown in FIG. 6 . In other examples, the first width of the monopolar wedge electrode near its proximal end may be smaller than the second width near its distal end.

In the illustrated example, the distal end of the conductive member 30134 is proximal to the distal end of the flexible flex circuit board 30132, which in turn is proximal to the distal end of the jaw 30130. However, in other examples, the distal end of the jaw 30130, the conductive member 30134, and the flexible flex circuit board 30132 are integrated in one location.

8-10 show an electrosurgical instrument 30200 including a first jaw 30210, a second jaw 30220, and a monopolar electrode 30230. The first jaw 30210 and the second jaw 30220 are movable between an open position and a closed position, and tissue is configured to be positioned therebetween. The first jaw 30210 and the second jaw 30220 may be constructed of metal and 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 shrink tubing. In various aspects, the jaws 30210, 30220 define a bipolar electrode that is electrically insulated from the monopolar electrode 30230.

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

Further to the above, when the monopolar electrode 30230 is energized by a generator (e.g., generators 1100, 900), the monopolar electrode 30230 is utilized to cut tissue positioned between the first jaw 30210 and the second jaw 30220. The monopolar electrode 30230 comprises a wire that extends along the first jaw 30210 and within the first flexible member 30240. The monopolar electrode 30230 exits the first flexible member 20140 through a proximal opening 30242 of 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 a distal opening 30244 of 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. Furthermore, the central portion 30232 of the monopolar electrode 30230 is reinforced along its length by the first flexible member 30240. In other words, the first flexible member 30240 applies a biasing force to the central portion 30232 of the monopolar electrode 30230 toward the second jaw 30220. The first flexible member 30240 increases the pressure exerted on tissue by the monopolar electrode 30230 when the first jaw 30210 and the second jaw 30220 grasp tissue therebetween, improving the cutting capabilities of the monopolar electrode 30230.

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

FIG. 11 shows a surgical instrument 30300 comprising 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 therebetween. The first jaw 30310 comprises a first bipolar electrode, and the second jaw 30320 comprises a second bipolar electrode. The first and second bipolar electrodes cooperate to deliver bipolar energy to cauterize and/or seal tissue grasped between the first jaw 30310 and the second jaw 30320 in a bipolar tissue treatment cycle.

Further 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 flexible or biasing member 30340 therein. The first biasing member 30340 is configured to bias tissue T toward the second jaw 30320 when tissue T is grasped between the first jaw 30310 and the second jaw 30320. The second jaw includes a second recess 30322 configured to receive a second flexible or biasing member 30350 and a monopolar electrode 30330 therein. The second biasing member 30350 is configured to bias the monopolar electrode 30330 and tissue T toward the first jaw 30310 when tissue T is grasped between the first jaw 30310 and the second jaw 30320.

Further to the above, the first recess 30312 and the second recess 30322 are sized and shaped to receive the first biasing member 30340, the second biasing member 30350, and the monopolar electrode 30330, such that the first jaw 30310 and the second jaw 30320 can be fully closed. In other words, when the first jaw 30310 and the second jaw 30320 are in the closed position, the first tissue contacting surface 30314 and the second tissue contacting surface 30324 contact each other when no tissue T is positioned therebetween. However, other embodiments are contemplated in which a gap is defined between the first tissue contacting surface 30314 and the second tissue contacting surface 30324 when the first jaw 30310 and the second jaw 30320 are in the closed position and when tissue T is positioned therebetween and/or when no tissue T is positioned therebetween. In either case, the first recess 30312 and the second recess 30322 are sized and/or shaped to enhance the ability of the monopolar electrode 30330 to extend over the second tissue contacting surface 30324 and into the first recess 30312 of the first jaw 30310 to fully close the first jaw 30310 and second jaw 30320. The first and second recesses 30312, 30322 include an electrically insulating material to electrically insulate the monopolar electrode 30330 from the first and second jaws 30310, 30320. However, other embodiments are envisioned in which the first and second recesses 30312, 30322 do not electrically insulate the monopolar electrode 30330 from the first and second jaws 30310, 30320. The monopolar electrode 30330 includes an independent wiring connection to the control housing of the surgical instrument 30300. The independent wiring connection allows the monopolar electrode 30330 to be energized independently of the first and second electrodes of the first and second jaws 30310, 30320 to perform cutting and/or sealing operations independently of one another. In at least one embodiment, the control housing of the surgical instrument 30300 prevents the monopolar electrode 30330 from being energized until the first and second electrodes of the first and second jaws 30310, 30320 have been energized to prevent cauterization and/or cutting of unsealed tissue T.

12 illustrates a surgical end effector 30400 for use with an electrosurgical instrument. The end effector 30400 includes a first jaw including a first bipolar electrode 30410, a second jaw including 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 flexible member and/or flexible insulator 30440. The flexible insulator 30440 may include rubber, silicone, polytetrafluoroethylene (PTFE) tubing, and/or combinations thereof. The monopolar electrode 30430 is attached to the flexible insulator 30440 of the first bipolar electrode 30410. Thus, the monopolar electrode 30430 is electrically isolated 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 tubing, and the second flexible insulator 30440 surrounding the second electrode 30420 comprises a silicone and/or rubber material. Other embodiments are contemplated, for example, 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.

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 open and closed positions to grasp tissue therebetween. The first jaw 30510 is at least partially surrounded by a first flexible member 30514, and the second jaw 30520 is at least partially surrounded by a second flexible member 30524. The first flexible member 30514 is substantially completely surrounded by a first bipolar electrode 30512, and the second flexible member 30524 is substantially completely surrounded by a second bipolar electrode 30522. More specifically, the first bipolar electrode 30512 surrounds the first flexible member 30514, except for a gap portion 30516 where the monopolar electrode 30530 is secured to the first flexible member 30514. Additionally, the second bipolar electrode 30522 surrounds the second flexible member 30524, except for a gap portion 30526 facing the first jaw 30510. The gap portion 30526 of the second jaw 30520 allows the monopolar electrode 30530 extending from the first flexible member 30514 to receive a biasing force from both the first flexible member 30514 and the second flexible member 30524 when the first jaw 30510 and the second jaw 30520 are in the closed position to grasp tissue. The first flexible member 30514 and the second flexible member 30524 comprise an electrically insulating material to electrically insulate the monopolar electrode 30530 from the first bipolar electrode 30512 and the second bipolar electrode 30522. The first and second flexible members 30514, 30524 may comprise rubber, silicone, PTFE tubing, and/or combinations thereof.

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 movable between an open position and a closed position to grasp tissue therebetween. 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. The first flexible member 30614 is substantially completely surrounded by a first bipolar electrode 30612, and the second flexible member 30624 is substantially completely surrounded by a second bipolar electrode 30622. In other words, the first bipolar electrode 30612 surrounds the first flexible member 30614, except for a gap portion 30616 where the monopolar electrode 30630 is secured to the first flexible member 30614. Additionally, the second bipolar electrode 30622 surrounds the second flexible member 30624, except for a gap portion 30626.

Further to the above, gap portions 30616, 30626 of the first and second bipolar electrodes 30612, 30622 allow the monopolar electrode 30630 extending from the first flexible member 30614 to contact the second flexible member 30624 when the first jaw 30610 and the second jaw 30620 are in the closed position. Furthermore, the gap portions 30616, 30626 are offset, allowing the first bipolar electrode 30612 to contact the second flexible member 30624 and the second bipolar electrode 30622 and contact the first flexible member 30614 when the jaws 30610, 30620 are closed and no tissue is positioned therebetween. Unlike the electrodes 30512, 30533, the electrodes 30612, 30622 are not mirror images of each other. Instead, electrode 30612 is offset from electrode 30622, and gap portions 30616, 30610 are also offset from one another. This arrangement prevents short circuits.

In either case, when the first jaw 30610 and the second jaw 30620 are closed, the monopolar electrode 30630 is positioned between the first flexible member 30614 and the second flexible member 30624 to provide a spring bias or biasing force to the monopolar electrode 30630 when tissue is grasped between the jaws 30610, 30620. In other words, the monopolar electrode 30630 receives a biasing force from both the first flexible member 30614 and the second flexible member 30624 when the first jaw 30610 and the second jaw 30620 are closed around tissue. The biasing force from the flexible members 30614, 30624 facilitates cutting of tissue when the monopolar electrode 30630 is energized.

Further to the above, in at least one embodiment, the first flexible member 30614 and the second flexible member 30624 comprise an electrically insulating material to electrically insulate the monopolar electrode 30630 from the first bipolar electrode 30612 and the second bipolar electrode 30622. In at least one embodiment, the first and second flexible members 30614, 30624 can comprise rubber, silicone, PTFE tubing, and/or combinations thereof.

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 movable between open and closed positions to grasp tissue therebetween. The first jaw 30710 defines a first hyperbolic electrode, and the second jaw 30720 defines a second bipolar electrode, cooperatively configured to deliver bipolar energy to cauterize and/or seal tissue grasped between the first jaw 30710 and the second jaw 30720. Additionally, the first jaw 30710 includes a first longitudinal recess 30712 having a first flexible member 30714 mounted therein. The second jaw 30720 includes a second longitudinal recess 30722 having a second flexible member 30724 mounted therein. The surgical end effector 30700 further comprises a monopolar electrode 30730 secured to the first flexible member 30714. The first flexible member 30714 and the second flexible member 30724 allow the monopolar electrode 30730 extending from the first flexible member 30714 to receive a biasing force from both the first flexible member 30714 and the second flexible member 30724 when the first jaw 30710 and the second jaw 30720 are in the closed position to grasp tissue. The first flexible member 30714 and the second flexible member 30724 comprise an electrically insulating material to electrically insulate the monopolar electrode 30730 from the first electrode of the first jaw 30710 and the second electrode of the second jaw 30720. The first and second flexible members 30714, 30724 can comprise rubber, silicone, PTFE tubing, and/or combinations thereof.

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 open and closed positions to grasp tissue therebetween. 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 jaw 30810 and the second jaw 30820. Additionally, the first jaw 30810 includes a longitudinal recess 30812 with a flexible member 30814 mounted therein. In at least one embodiment, the second jaw 30820 comprises stainless steel coated with PTFE shrink tubing. The surgical end effector 30800 further includes a monopolar electrode 30830 secured to a flexible member 30814 of the first jaw 30810. The flexible member 30814 provides a biasing force to the monopolar electrode 30830 when the first jaw 30810 and the second jaw 30820 grasp tissue therebetween. The biasing force of the flexible member 30814 enhances contact between the monopolar electrode 30830 and tissue during a cutting operation. The flexible member 30814 includes an electrically insulating material to electrically insulate the monopolar electrode 30830 from the first electrode of the first jaw 30810. The flexible 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, but the monopolar electrode 30830 is fixed to the second jaw 30820. When tissue is positioned between the first jaw 30810 and the second jaw 30820, the flexible member 30814 applies a biasing force through the tissue to the monopolar electrode 30830 attached to the second jaw 30820.

18 illustrates a surgical end effector 30900 for use with an electrosurgical instrument. The surgical end effector 30900 defines an end effector axis EA extending longitudinally along the length of the end effector 30900. The surgical end effector 30900 includes a first jaw 30910 and a second jaw 30920 movable between an open position and a closed position to grasp tissue therebetween. The first jaw 30910 includes a first honeycomb lattice structure 30912 surrounded by a first diamond-like coating 30914. The second jaw 30920 includes a second honeycomb lattice structure 30922 surrounded by a second diamond-like coating 30924. The diamond-like coatings 30914, 30924 may be, for example, any of the diamond-like coatings described herein. The first honeycomb lattice structure 30912 and the second honeycomb lattice structure 30922 comprise the same geometric arrangement and materials. However, other embodiments are contemplated in which the first honeycomb lattice structure 30912 and the second honeycomb lattice structure 30922 comprise different geometric arrangements and materials, including more or fewer air pockets, as described herein. The first diamond-like coating 30914 and the second diamond-like coating 30924 comprise the same materials. However, other embodiments are contemplated in which the first diamond-like coating 30914 and the second diamond-like coating 30924 comprise different materials.

In addition to the above, the end effector 30900 further includes a first bipolar electrode 30940 secured to the first diamond-like coating 30914 of the first jaw 30910 on a first side of the end effector axis EA. The first bipolar electrode 30940 extends longitudinally along the length of the end effector 30900. The second jaw 30920 includes a flexible member 30960 mounted within a cutout portion 30926 defined in the second jaw 30920. The end effector 30900 further includes a second bipolar electrode 30950 mounted to the flexible member 30960 on a second side of the end effector axis EA. The second bipolar electrode 30950 extends longitudinally along the length of the end effector 30900. The electrodes 30940, 30950 cooperate to deliver bipolar energy to tissue grasped between the jaws 30910, 30920. Additionally, the electrodes 30940, 30950 are offset from one another to prevent accidental contact between them in the closed position, which could create a short circuit.

The end effector 30900 further includes a monopolar electrode 30930 attached to the flexible member 30960 and positioned intermediate the first bipolar electrode 30940 and the 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 discussed herein, the first bipolar electrode 30940 and the second bipolar electrode 30950 are configured to deliver bipolar energy to the tissue in a bipolar energy cycle, thereby cauterizing and/or sealing the tissue when the tissue is positioned between the first jaw 30910 and the second jaw 30920. Additionally, the monopolar electrode 30930 is configured to cut the tissue by delivering monopolar energy to the tissue in a monopolar energy cycle.

Further to the above, the flexible member 30960 is compressible and applies pressure to tissue positioned between the first jaw 30910 and the second jaw 30920. More specifically, the pressure applied by the jaws 30910, 30920 on tissue in the area directly above the flexible member 30960 is greater than the pressure applied to tissue in the area adjacent to the flexible member 30960 (i.e., the area where the flexible member 30960 is not present). In at least one embodiment, the flexible member 30960 comprises an elastomeric and/or plastic honeycomb structure that insulates the second bipolar electrode 30950 and the monopolar electrode 30930 from the second diamond-like coating 30924 and the honeycomb lattice structure 30922 of the second jaw 30920. The flexible member 30960 holds the second bipolar electrode 30950 and the monopolar electrode 30930 in place and provides a biasing force on the monopolar electrode 30930 and the second bipolar electrode 30950 toward the first jaw 30910 when tissue is grasped between the first jaw 30910 and the second jaw 30920.

In addition to the above, the first and second diamond-like coatings 30914, 30924 are electrically conductive and thermally insulating. However, other embodiments are envisioned in which the first and second diamond-like coatings 30914, 30924 are electrically insulating and/or thermally insulating. The first and second honeycomb lattice structures 30912, 30922 include air pockets that provide thermal insulation to the first and second jaws 30910, 30920. The first and second honeycomb lattice structures 30912, 30922 provide an 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 lattice 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 force of the first and second honeycomb lattice structures 30912, 30922 and the flexible member 30960 provides consistent pressure on tissue as it is grasped between the first jaw 30910 and the second jaw 30920.

In various aspects, one or more of the diamond-like coatings (DLC) 30914, 30924 are composed of an amorphous carbon-hydrogen network with graphite and diamond bonds between carbon atoms. The DLC coatings 30914, 30924 can form films around the first and second honeycomb lattice structures 30912, 30922 that have low friction and high hardness properties. The DLC coatings 30914, 30924 can be doped or undoped and are generally in the form of amorphous carbon (a-C) or hydrogenated amorphous carbon (a-C:H), containing a majority of sp3 bonds. Various surface coating techniques, such as those developed by Oerlikon Balzers, can be used to form the DLC coatings 30914, 30924. In at least one example, the DLC coatings 30914, 30924 are produced using plasma-assisted chemical vapor deposition (PACVD).

In various embodiments, one or both of the DLC coatings may be replaced with a coating including titanium nitride, chromium nitride, Graphit iC™, or any other suitable coating.

With further reference to FIG. 18 , the electrodes 30940, 30950 extend along the axis EA and are offset such that a plane intersecting the monopolar electrode 30930 extends between the electrodes 30940, 30950. Furthermore, in the illustrated example, the electrodes 30930, 30940, 30950 protrude from the outer surfaces of the jaws 30910, 30920. However, in other examples, one or more of the electrodes 30930, 30940, 30950 can be recessed in the jaws 30910, 30920 such that their outer surfaces are flush with the outer surfaces of the jaws 30910, 30920.

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

Figure 19 is a graph illustrating an alternative example of a tissue treatment cycle 31000 that delivers bipolar energy to tissue in a bipolar energy cycle and monopolar energy to tissue in a monopolar energy cycle. The tissue treatment cycle 31000 includes a bipolar-only phase 31002, a blended energy phase 31004, and a monopolar-only phase 31006. The tissue treatment cycle 31000 can be performed, for example, by an electrosurgical system that includes a generator (e.g., generators 1100, 900) coupled to an electrosurgical instrument that includes an end effector (e.g., the end effector of Figures 4-18).

The graph in FIG. 19 shows power (W) on the y-axis and time on the x-axis. The power values provided on the graph and its description below are non-limiting examples of power levels that may be utilized in tissue treatment cycle 31000. Other suitable power levels are also contemplated by the present disclosure. The graph shows a bipolar power curve 31010 and a monopolar power curve 31014. Additionally, a blended power curve 31012 represents the simultaneous application of monopolar and bipolar energy to tissue.

With further reference to FIG. 19 , the initial tissue contact phase is shown between _t0 and _t1 and occurs prior to the application of any energy to the tissue. The jaws of the end effector are positioned on either side of the tissue to be treated. Bipolar energy is then applied to the tissue through a tissue coagulation phase beginning at _t1 and ending at _t4 . During the feathering segment ( _t1 - _t2 ), the application of bipolar energy is increased to a predetermined power value (e.g., 100 W) and maintained at the predetermined power value for the remainder of the feathering segment ( _t1 - _t2 ) and the tissue heating segment ( _t2 - _t3 ). During the sealing segment ( _t3 - _t4 ), the bipolar energy application is gradually decreased. The bipolar energy application ends at the end of the sealing segment ( _t3 - _t4 ) and before the beginning of the cutting/ablation phase.

In addition to the above, monopolar energy application to the tissue is activated during the tissue coagulation phase. In the example shown in Figure 19, activation of monopolar energy begins at time _t2 , at the end of the feathering segment and the beginning of the tissue heating segment. As with the bipolar energy, monopolar energy application to the tissue is gradually increased to a predetermined power level (e.g., 75 W) and maintained for the remainder of the tissue heating segment and the initial portion of the sealing segment.

During the sealing segment of the tissue coagulation phase ( _t3 - _t4 ), the power of monopolar energy application to the tissue gradually increases as the power of bipolar energy application to the tissue gradually decreases. In the illustrated example, the application of bipolar energy to the tissue is stopped at the end of the tissue coagulation cycle ( _t4 ). The initiation of the tissue ablation phase begins with an inflection point in the monopolar power curve 31014 at _t4 , where the monopolar energy received during the sealing segment ( _t3 - _t4 ) has gradually increased to this point, followed by a step up to a predetermined maximum threshold power level (e.g., 150 W) sufficient to ablate the coagulated tissue. The maximum power threshold is maintained for a predetermined period of time, terminating with the monopolar power level returning to zero.

Thus, the tissue treatment cycle 31000 is configured to deliver three different energy modalities to the tissue treatment region at three consecutive times. A first energy modality, including bipolar energy but not monopolar energy, is applied to the tissue treatment region during a feathering segment from _t1 to _t2 . A second energy modality, a blended energy modality including a combination of monopolar and bipolar energy, is applied to the tissue treatment region during a tissue heating segment and a tissue sealing segment from _t2 to _t4 . Finally, a third energy modality, including monopolar energy but not bipolar energy, is applied to the tissue during a cutting segment from _t4 to _t5 . Furthermore, the second energy modality includes a power level that is the sum of the power levels of the monopolar and bipolar energy. In at least one example, the power level of the second energy modality includes a maximum threshold (e.g., 120 W). In various aspects, the monopolar and bipolar energy may be delivered to the end effector from two different generators.

The blended power curve 31012 applied during the blended energy phase 31004 represents the application of a combination of bipolar and monopolar energy to tissue. During the tissue heating segment ( _t - _t ), the blended power curve 31012 ramps up at _t when monopolar power is activated, and the bipolar power is maintained at a constant, or at least substantially constant, level for the remainder of the tissue heating segment ( _{t , t} ) and the beginning of the tissue sealing segment (t- _t ). During the sealing segment (t _{- t} ), the blended power curve 31012 is maintained at a constant, or at least substantially constant, level by gradually decreasing the bipolar power level as the monopolar power level increases.

In various aspects, the bipolar and/or monopolar power levels of the tissue treatment cycle 31000 can be adjusted based on one or more measured parameters, such as tissue impedance, jaw motor speed, jaw motor force, end effector jaw opening, and/or motor current draw resulting in end effector closure.

According to at least one embodiment, a monopolar electrode for cutting patient tissue includes a monopolar cam lobe electrode and a wire attached thereto. The monopolar cam lobe electrode is initially positioned at the distal end of the end effector of the electrosurgical instrument. When a clinician desires to cut patient tissue, the monopolar cam lobe electrode is energized (i.e., via a generator, as discussed herein) and pulled by its attached wire. The wire initially guides the cam lobe electrode to rotate upward along 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 a pivoting cutting blade is positioned at the distal end and then pulled proximally, the cam lobe electrode acts like a pivoting cutting blade on a surgical instrument. Furthermore, 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 is initially rotated to an upright position. The cam lobe electrode exerts a force perpendicular to the opposite side of the end effector jaw from where the cam lobe electrode is positioned. In such a configuration, the cam lobe electrode can initially be hidden from the tissue gap between the jaws of the end effector until the wire first pulls on the cam lobe electrode, rotating it to its upright position. Because the cam lobe electrode is initially hidden, the load 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 is either substantially upright before beginning its distal to proximal movement, or the cam lobe electrode is partially erect before beginning its distal to proximal movement. The amount the cam lobe electrode rotates toward its upright 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 resists rotating the cam lobe electrode to its upright position more than softer tissue before the cam lobe electrode begins to move from the distal end toward the proximal end.

20 shows an electrosurgical instrument 40100 comprising a housing, a shaft 40110 extending from the housing, and an end effector 40120 extending from the shaft 40110. An articulation joint 40130 rotatably connects the shaft 40110 and the end effector 40120 to facilitate articulation of the end effector 40120 relative to the shaft 40110. A circuit board 40140 is located within the housing of the instrument 40100. However, other embodiments are envisioned with the circuit board 40140 positioned in any suitable location. In at least one example, the circuit board 40140 is a printed circuit board. The printed circuit board 40140 includes a connection plug 40142 for connecting the printed circuit board 40140 to a wiring assembly 40150. The wiring assembly 40150 extends from the printed circuit board 40140, through the shaft 40110, and into the 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, the compression rate of the jaws of the end effector 40120 and/or the thermal cycle of the end effector 40120. In the illustrated example, the wiring assembly 40150 includes a sensor 40122 positioned within the end effector 40120. The sensor 40122 monitors at least one function of the end effector 40120.

In various aspects, the sensor 40122 may comprise 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, the circuit board 40140 comprises a control circuit including a microcontroller having a processor and a memory unit. The memory unit may store one or more algorithms and/or lookup tables for recognizing certain parameters of the end effector 40120 and/or tissue grasped by the end effector 40120 based on measurements provided by the sensor 40122.

In addition to the above, the wiring assembly 40150 may include several flexible, rigid, and/or stretchable sections as part of the flexible circuit to allow the wiring assembly 40150 to bend, flex, and/or stretch across various component boundaries and/or junctions of the surgical instrument 40100. For example, as the wiring assembly 40150 crosses a component boundary or junction, a non-stretchable flexible plastic substrate (i.e., polyimide, PEEK, transparent conductive polyester film) transitions to a flexible silicone or elastomeric substrate and then back to a non-stretchable flexible substrate on the other side of the junction. The metal conductors within the wiring assembly 40150 remain continuous but are stretchable across the component boundaries and/or junctions. This arrangement, with localized portions that are flexible in at least two planes, allows the entire circuit to be flexible. Thus, the portion of the wiring assembly 40150 that spans the component boundaries and/or joints allows for localized relative motion without pulling the wiring assembly 40150 apart or losing its continuity. The wiring assembly 40150 is secured around the localized motion zone to protect the wiring assembly 40150 from excessive strain and/or distortion.

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

In addition to the above, the wiring assembly 40150 further comprises electrical traces or conductors 40160 configured to carry electrical energy between the printed circuit board 40140 and the end effector 40120 along the length of the wiring assembly 40150. Referring primarily to FIGS. 21 and 22 , the conductors 40160 comprise an elastic portion 40162 spanning the elastic portions 40152, 40156. The elastic portion 40162 comprises a serpentine, oscillating, and/or zigzag pattern that allows the elastic portion 40162 to stretch when the elastic portions 40152, 40156 are stretched as illustrated in FIG. 22 . When the elastic portions 40152, 40156 return to their relaxed and/or natural state, the elastic portion 40162 returns to its serpentine, oscillating, and/or zigzag pattern, as shown in FIG. 21 .

Further to the above, in at least one embodiment, the conductor 40160 may be used in high current applications, such as RF processing energy, where the conductor 40160 comprises copper conductors printed on the wiring assembly 40150 in a serpentine, oscillating, and/or zigzag pattern. Other embodiments are envisioned in which the stretchable portion 40162 of the conductor 40160 across the elastic portions 40152, 40156 includes a conductive link that connects the stretchable portion 40162 to allow the stretchable portion 40162 to extend across a joint.

FIG. 23 shows an electrosurgical instrument 40200 comprising a shaft 40210, a translation member 40220, and a flex circuit and/or wiring harness 40230. The wiring harness 40230 may be similar to the wiring assembly 40150. The translation member 40220 may be, for example, a knife drive rod for cutting patient tissue, an articulation cable, and/or a rigid articulation member of the instrument 40200. However, the translation member 40220 may be any translation member as described herein. In any case, the translation member 40220 is configured to translate relative to the shaft 40210 and comprises an iron element 40222 that translates with the translation member 40220. The iron element 40222 may be attached to or housed within the translation member 40220, for example. The wiring harness 40230 is secured within the shaft 40210 and includes a linear inductive sensor 40232 configured to detect the linear position of the ferrous element 40222 and, therefore, the linear position of the translational member 40220. More specifically, the linear inductive sensor 40232 is configured to generate an electric field that causes the ferrous element 40222 to break down. The linear inductive sensor 40232 is integrated into the wiring harness 40230 to provide robust protection from external elements 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 circuit a includes a microcontroller having a processor and a memory unit that stores one or more algorithms and/or lookup tables for recognizing certain parameters of the surgical instrument 40200 and/or tissue being processed by the surgical instrument 40200 based on measurements provided by the sensor 40232.

24 and 25 show an electrosurgical instrument 40300 comprising a shaft 40310, a translation member 40320, and a flex circuit or wiring harness 40330. The translation member 40320 is configured to translate relative to the shaft 40310 to perform an end effector function. The translation member 40320 may be, for example, a knife drive rod for cutting patient tissue, an articulation cable, and/or a rigid articulation member of the instrument 40300. However, the translation member may be, for example, any translation member described herein. In any case, the wiring harness 40330 comprises a conductor 40331, a body portion 40332, and an elastic portion 40334 extending from the body portion 40332. The body portion 40332 is secured to the shaft 40310 and comprises a first sensor 40340 configured to measure the function of the end effector of the surgical instrument 40300. The elastic portion 40334 is attached to the translational member 40320 and includes a second sensor 40350. The second sensor 40350 is positioned at the end of the elastic portion 40334 where the elastic portion 40334 is attached to the translational member 40320. Thus, the second sensor 40350 translates with the translational member 40320. The second sensor 40350 is configured to measure stress and/or strain within the translational member 40320. However, other embodiments are envisioned in which the second sensor is configured to measure the position, velocity, and/or acceleration of the translational member 40320.

In various aspects, the control circuit a includes a microcontroller having a processor and a memory unit that stores one or more algorithms and/or lookup tables for recognizing particular parameters of the surgical instrument 40300 and/or tissue to be treated by the surgical instrument 40300 based on measurements provided by the sensors 40340, 40350.

In addition to the above, the elastic portion 40334 is similar to the elastic portions 40152, 40156 discussed herein with respect to Figures 20-22. More specifically, the elastic portion 40334 comprises a resilient portion and/or a stretchable portion that allows the elastic portion 40334 to bend, flex, and/or stretch relative to the main body portion 40332 of the wiring harness 40330. Such an arrangement allows the second sensor 40350 to be integrated into the wiring harness 40330 without the detected measurements of the second sensor 40350 being affected by movement of the translation member 40320 relative to the wiring harness 40330.

Figures 26-33 show an electrosurgical instrument 40400 comprising 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 comprises 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 per input from a control circuit 40413 and in response to actuation movement of the trigger 40412. In various aspects, the control circuit 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 and the microcontroller 40414 to provide power to the motor.

The shaft 40420 defines a shaft axis SA and includes an end effector drive member, such as the end effector drive member 40419. The end effector drive member 40419 is operatively responsive to an electric motor 40411a in the handle 40410 and is configured to perform at least two end effector functions. As discussed herein, the end effector 40430 is configured to be selectively locked and unlocked from the shaft 40420. 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. Additionally, 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 the electric motor, the end effector drive member 40419 rotates the end effector 40430 about the shaft axis SA.

The instrument 40400 further comprises a manual toggle member or rocker member 40440, an elongated shaft 40450, and a tensioning cable 40460. The elongated shaft 40450 is crimped to the tensioning cable 40460 such that the elongated shaft 40450 and the tensioning cable 40460 move together along the shaft axis SA. The rocker member 40440 comprises a slot 40442 defined therein that is configured to receive the elongated shaft 40450. The rocker member 40440 and the elongated shaft 40450 are mounted within a handle 40410, with portions of the rocker member 40440 extending laterally beyond each side of the handle 40410 to allow the rocker member 40440 to be manually actuated by a clinician. The rocker member 40440 further comprises 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 biased) by a spring or the like.

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

As described above, the elongate shaft 40450 is crimped to the tensioning cable 40460. Accordingly, the tensioning cable 40460 retracts when the rocker member 40440 is rotated either clockwise (CW) or counterclockwise (CCW). The tensioning cable 40460 may be similar to the unlocking cable 11342 shown in FIG. 54 of U.S. Patent Application Attorney Docket No. END9234USNP2/190717-2. More specifically, when the tensioning cable 40460 is retracted (i.e., moved proximally), it unlocks the end effector 40430, allowing the end effector 40430 to rotate and/or articulate relative to the shaft 40420. Thus, when the rocker member 40440 is rotated in either a clockwise direction CW or a counterclockwise direction CCW, the end effector 40430 is unlocked to allow rotation and/or articulation of the end effector 40430.

In addition to the above, the rocker member 40440 further includes a downwardly extending post 40446 configured to engage a first switch 40447 and a second switch 40448 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 clockwise (CW), the tension cable 40460 retracts to unlock the end effector 40430, and the post 40446 engages the first switch 40447, resulting in rotation of the motor 40411a in a first direction, which causes the articulation drive assembly 40417 to articulate the end effector 40430, e.g., to the right. As the rocker member 40440 rotates counterclockwise CCW, the tension cable 40460 retracts, unlocking the end effector 40430. The post 40446 engages the second switch 40448, which causes the motor 40411a to rotate in a second direction opposite the first direction, causing the articulation drive assembly 40417 to articulate the end effector 40430 to the left.

28 , when the rocker member 40440 is centered, neither the first switch 40447 nor the second switch 40448 is activated. The tension cable 40460 is in its distal-most position, which corresponds to the end effector 40430 being locked, as described above. In various aspects, any suitable shifter or clutch mechanism may 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 shifter mechanism may be operated by the rocker member 40440 such that the drive member 40419 is operatively coupled to the closure/firing drive assembly 40421 when the rocker member 40440 is centered and operatively coupled to the articulation drive assembly 40417 when the rocker member 40440 is rotated from the center position in either a clockwise direction (CW) or a counterclockwise direction (CCW).

When the end effector 40430 is locked, rotation of the electric motor within the handle 40410 causes rotation of the end effector drive member 40419, which, via the closing/firing drive assembly 40421, moves the pair of jaws of the end effector 40430 between open and closed positions. However, other embodiments are envisioned in which 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 either case, rotation of the rocker member 40440 in either a clockwise direction (CW) or a counterclockwise direction (CCW) unlocks the end effector 40430, allowing rotation of the end effector 40430 about the shaft axis SA. More specifically, when the end effector 40430 is unlocked, the end effector drive member 40419 is actuated by an electric motor 40411a in the handle 40410, causing the end effector 40430 to rotate about the shaft axis SA relative to the shaft 40420.

In addition to the above, other embodiments are contemplated that include two or more articulation motors, where the articulation motors are operatively responsive to a first switch 40447 and a second switch 40448. Such a configuration facilitates articulation of the end effector 40430 about multiple axes, for example, when a double articulation joint is used between the end effector 40430 and the shaft 40420. Other embodiments are also contemplated that include separate motors dedicated to closing, firing, and/or articulation.

In various aspects, the motor driver 40411b is configured to operate the electric motor 40411a in multiple operating states based on input from the processor 40416. For example, when the end effector drive member 40419 opens or closes the jaws of the end effector 40430 (i.e., the distal head or end effector 40430 is locked), the electric motor is in a first operating mode. When the electric motor 40411a is in the first operating mode, the end effector drive member 40419 is operated at a first speed, a first amount of change, a first amount of torque, and/or a first amount of acceleration to open or close the jaws of the end effector 40430. 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 a second operating mode. When the electric motor 40411a is in the second operating mode, the end effector drive member 40419 is operated at a second speed, a second rate of change, a second amount of torque, and/or a second amount of acceleration to rotate the end effector 40430.

In at least one embodiment, the first and second operating modes are different, e.g., include different combinations of control parameters for driving the end effector drive member 40419 at different speeds, torques, and/or accelerations. In at least one embodiment, the second operating mode (i.e., distal head rotation) includes, e.g., a lower maximum torque limit, incremental acceleration to allow for precise adjustments, and/or a lower maximum torque speed than the first operating mode. In contrast, the end effector drive member 40419 includes, e.g., a higher torque limit, no or limited incremental acceleration, and/or rotates at a faster speed in the first operating mode.

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 operating mode or the second operating mode. For example, various combinations of control parameters for driving the end effector drive member 40419 at different speeds, torques, and/or accelerations can be selected by the processor 40416 from lookup tables, algorithms, and/or equations stored in the memory 40415.

29, in addition to the above, the 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, as described above, to articulate the end effector 40430 relative to the shaft axis SA. 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 control of the speed 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 with which the first switch 40447 or the second switch 40448 is depressed is directly proportional to the velocity, torque, and/or acceleration with which the end effector 40430 is articulated. Alternatively, in certain examples, the switches 40447 and 40448 are in direct communication with the motor driver 40411b.

As shown in FIG. 29 , various embodiments are contemplated in which the surgical instrument 40400 includes a transmission mechanism, shiftable motor drive, and/or shifter 40427 to drive the end effector drive shaft 40419 and, for example, the articulation drive assembly 40417, lock two drive mechanisms together, or lock the end effector drive shaft 40419 and the closure/firing drive assembly 40421, for driving the articulation of the end effector 40430. In such a configuration, the surgical instrument 40400 includes a single electric motor 40411a to drive the 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 the single electric motor between engagement with the articulation drive assembly 40417 and the closure/firing drive assembly 40421.

According to at least one embodiment, handle user control of the surgical instrument's motor and/or end effector movement is in signal communication with the surgical instrument's control system. The control system is housed within the handle and couples user trigger feedback to the end effector's motor drive feedback 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 tactile feedback and trigger sweep correlation. Additionally, the surgical instrument includes a feedback system to the control system for monitoring alternative compression or pressure within the jaws to offset the elimination of tactile feedback. In such a configuration, manual user input drives the jaws independently of trigger stroke. In at least one embodiment, a smaller, finger-sized trigger with a spring return is utilized to improve manual control and handle maneuverability. Additionally, in at least one embodiment, modular attachment of the electrical backbone to the surgical instrument is used when new single-use shafts are introduced.

FIG. 35 shows a graph 40500 of a power schematic of a surgical system 40550 (FIG. 34) including an electrosurgical instrument 40551 and a power source (e.g., generator) 40552 configured to provide power to the electrosurgical instrument 40551. The electrosurgical instrument 40551 includes an integrated, or self-contained, power source that functions in cooperation with a separate generator 40552 to power the power motor and other components of the electrosurgical instrument 40551. The integrated power source includes a power storage device, such as, for example, a rechargeable, non-removable battery 40553. The battery 40553 is configured to begin recharging as soon as the battery 40553 is attached to the output of the generator 40552. The integrated power source can begin recharging upon use, for example, during a procedure. The integrated power supply, 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 sensors until the rechargeable battery 40553 is charged to a predetermined maximum level. The battery 40553 can simultaneously discharge to operate the controls or motor of the electrosurgical instrument 40551 and charge via the power output generator 40552. The battery 40553 continues to charge until a predetermined level is reached during user-requested operation during generator initialization or standby during use. When the battery 40553 is used to a predetermined minimum level, the user is notified that they must wait a period of time for the battery 40553 to charge above a minimum threshold level before the electrosurgical instrument 40551 can be used again.

In addition to the above, graph 40500 of FIG. 35 includes graphs 40502, 40504, 40506, and 40508, each including a Y-axis representing various parameters of the surgical system 40550 plotted against time t on the X-axis. Graph 40502 shows on the Y-axis the power (Watts (W)) supplied by the generator 40552 (e.g., an internal battery, such as a rechargeable battery 40553) to the power source of the electrosurgical instrument. Graph 40504 shows on the Y-axis the charge level of the battery 40553 as a percentage of a maximum charge level threshold. Graph 40506 shows on the Y-axis the power (Watts (W)) consumed from the battery 40553 by a component of the surgical instrument 40551, such as, for example, the motor 40554. Graph 40508 shows on the Y-axis the set motor speed limit as a percentage of a maximum motor speed threshold.

In the illustrated example, the electrosurgical instrument 40551 is connected to the generator 40552 at time _t0 . The generator 40552 charges the rechargeable battery 40553 at a constant recharge rate (S1) until the charge level of the battery 40553 reaches a maximum threshold of 100% (achieved at _t1 ). Power delivery by the generator 40552 begins automatically upon connection of the surgical instrument 40551 to the generator 40552 and is automatically stopped when the charge level reaches the maximum threshold. In various examples, the surgical system 40550 includes a control circuit 40555 that includes a charge meter 40556 for detecting the charge level of the battery 40553 and a switching mechanism for stopping power delivery to the surgical instrument 40551 when the charge level reaches the maximum threshold. In at least one example, the battery can be charged at a constant rate of 15 W. The generator will automatically stop charging the battery 40553 when the battery charge level reaches 100%.

Additionally, at time _t2 , 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 it to discharge at a rate _S2 . The battery 40553 continues to charge while discharging power to the motor 40554. The discharge rate _S2 is therefore derived from a combination of the discharge rate of the battery 40553 due to the motor drawing power from the battery and the charge rate of the battery 40553 due to the power supplied to the battery 40553 by the generator 40552, occurring in parallel or simultaneously until the motor 40554 is stopped. Once power consumption 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 actuated in first and second instances 40501, 40503, as shown in 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 several times to achieve a good grasp of the tissue. At the end of the second instance 40503 of motor actuation, the battery 40553 returns to recharge to a 100% charge level, which is achieved at _t3 at a constant rate S1, at which point power supplied to the battery 40553 by the generator 40552 is terminated. Additionally, a third instance 40505 of motor actuation to articulate the end effector 40557 discharges the battery 40553 at a rate _S3 from time _t4 to time _t5 . The end effector closure/opening and articulation may be driven by the same or different motors that draw power from the battery 40553.

Further, as shown in graphs 40504, 40506, the fourth, fifth, sixth, and seventh instances 40507, 40509, 40511, 40513 of motor actuation 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, in signal communication with the generator 40552 and the battery 40553, maintains the motor speed limit at 100% until the battery charge level decreases to the first predetermined threshold level. When the charge level of the battery 40553 decreases to the first predetermined level, for example, 40% at time _t6 , the motor controller 40558 reduces the motor speed limit (e.g., 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 closes the jaws of the end effector 40557 at a first reduced speed, making time tb of motor actuation instance 40509 longer than time _{t a of} motor actuation instance 40507. Furthermore, when the charge level drops to a second predetermined level, for example, 20% at time _t7 , the motor controller 40558 reduces the motor's 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 clamps the jaws of the end effector 40557 at a second reduced speed that is slower than the first reduced speed, making time t _c of motor actuation instance 40513 longer than time t _b of motor actuation instance 40509. Thus, the motor controller 40558 causes the motor to perform similar functions at different speeds based on the corresponding charge level of the battery 40553 powering the motor 40554 .

Furthermore, when the charge level of the battery 40553 drops to a predetermined minimum level, for example, 10% at time _t8 , the motor speed limit is reduced to zero and the surgical instrument alerts the clinician to wait until the battery 40553 is charged above the predetermined minimum level, for example, 40% at time _t9 . When the battery 40553 is recharged from 10% to 40% and the jaws of the end effector 40557 are actuated in motor actuation instance 40515, the surgical instrument 40551 moves the jaws of the end effector 40557 at a first reduced speed at time _td , which is less than time ta. Upon completion of actuation instance 40515 at the end of time _td , the battery 40553 begins recharging at a constant recharge rate _S1 until it reaches a maximum charge level at _t10 , when power from the generator 40552 to the battery 40553 is stopped.

FIG. 34 is a simplified schematic diagram of a surgical system 40550 including a control circuit 40550 having a microcontroller 40560 including a processor 40561 and a memory 40562 that stores 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 is in communication with a charge meter 40556 configured to measure the charge level of the battery 40553. Furthermore, detecting that the charge level of the battery 40553 is below a first minimum charge level threshold (e.g., 40%) while the motor 40554 is operating causes the processor to reduce the maximum speed limit of the motor 40554 to the first maximum threshold. In at least one example, the processor 40561 is in communication with a motor driver 40558 configured to control the speed of the motor 40554. In such an example, the processor 40561 sends a signal to the motor driver 40558 to reduce the motor speed limit of the motor 40554 to the first maximum threshold. Alternatively, in other examples, the processor 40561 can directly control the maximum motor speed limit.

Further, detecting that the charge level of battery 40561 is below a second minimum charge level threshold (e.g., 20%) while motor 40554 is operating can cause the processor to reduce the maximum speed limit of motor 40554 to a second maximum threshold that is less than the first maximum threshold. Further, detecting that the charge level of battery 40553 is below a third minimum charge level threshold (e.g., 10%) while motor 40554 is operating can cause the processor to reduce the maximum speed limit of motor 40554 to zero or stop motor 40554. Processor 40561 can prevent motor 40554 from restarting until the minimum charge level is above a predetermined threshold, such as the second minimum charge level threshold (e.g., 20%).

In certain examples, the processor 40561 may further use one or more feedback systems 40563 to alert the clinician. In certain cases, the feedback system 40563 may include one or more visual feedback systems, such as, for example, a display screen, a backlight, and/or an LED. In certain cases, the feedback system 40563 may include one or more audio feedback systems, such as, for example, a speaker and/or a buzzer. In certain cases, the feedback system 40563 may include, for example, one or more tactile feedback systems. In certain cases, the feedback system 40563 may include, for example, a combination of visual, audio, and/or tactile feedback systems.

Further to the above, in at least one embodiment, the internal battery is charged during and/or after the surgical procedure by an external power storage device or by an external battery attached to the surgical instrument. In at least one embodiment, the external battery comprises, for example, a disposable battery introduced to the sterile field in a sterile package and attached to the surgical instrument to, for example, supplement and/or replace the internal battery. In at least one embodiment, the external battery is the sole operating power source for controlling the mechanical movement system, for example, while radio frequency (RF) power for therapeutic treatment of tissue is provided by a generator. In such a configuration, 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, rather than replacing, the internal battery. Furthermore, in at least one embodiment, the external battery comprises a disposable battery connected to the internal battery of the surgical instrument when the surgical instrument is not performing a surgical procedure to charge the internal battery. The external battery is then removed from the surgical instrument for later use by the clinician when supplemental power is needed.

FIG. 36 shows a surgical system 40600 comprising a surgical instrument 40610, a monopolar generator 40620, and a bipolar generator 40630. In the illustrated embodiment, the monopolar generator 40620 is electrically coupled directly to the motor 40650 of the surgical instrument 40610, and the bipolar generator 40630 is electrically coupled directly to the battery 40640. The bipolar generator 40630 is configured to charge the battery 40640, thereby providing power to the motor 40650. The monopolar generator 40620 is configured to directly power the motor 40650 and charge the battery 40640. More specifically, an additional electrical connection 40660 is provided between the monopolar generator 40620 and the battery, allowing the monopolar generator 40620 to power the motor 40650 while also powering and charging the battery 40640. The monopolar generator 40620 and the bipolar generator 40630 are configured to output DC power to the battery 40640 and the motor 40650.

In various aspects, the surgical instrument 40610 includes an end effector 40611. A motor 40650 is operatively coupled to the end effector 40611 and can be actuated to perform multiple functions, such as moving at least one of the jaws 40613, 40614 of the end effector 40611 to transition the end effector 40611 between an open configuration, as shown in FIG. 36 , and a closed configuration for grasping tissue therebetween. Furthermore, the end effector 40611 extends distally from a shaft 40615 and is articulatable relative to the shaft 40611 about a longitudinal axis extending centrally through the shaft 40615 by actuation motion generated by the motor 40650.

Additionally, the surgical instrument 40610 further comprises a power supply assembly 40616 that transmits power from the generators 40620 and 40630 to the motor 40650 and/or the battery 40640. In at least one example, the power supply assembly 40616 separately receives a first power from the generator 40620 and a second power from the generator 40630. The power supply assembly 40616 is configured to transmit the second power to the battery 40640 to charge the battery at a constant rate (S1) to a predetermined maximum charge level. The power supply assembly 40616 is further configured to transmit the first power to the electric motor 40650 and the battery 40650. In the illustrated example, the motor 40650 is powered in parallel or simultaneously by the battery 40640 and the generator 40620.

FIG. 37 shows a graph 40700 of the battery charge rate and motor torque of the surgical system 40600. Line 40710 represents the battery charge rate of the battery 40640 when only the bipolar generator 40630 is utilized with the surgical instrument 40610. Line 40720 represents the combined battery charge rate when both the monopolar generator 40620 and the bipolar generator 40630 are utilized with the surgical instrument 40610. When both the monopolar generator 40620 and the bipolar generator 40630 are used to charge the battery 40640, the battery 40640 charges at a faster rate than if only one of the monopolar generator 40620 and the bipolar generator 40630 were used to charge the battery 40640. Additionally, line 40730 represents the motor torque of the motor 40650 when only the bipolar generator 40630 is utilized with the surgical instrument 40610. Line 40740 represents the motor torque of the motor 40650 when both the homopolar generator 40620 and the bipolar generator 40630 are utilized with the surgical instrument 40610. When both the homopolar generator 40620 and the bipolar generator 40630 are used to power the motor 40650, the motor 40650 can generate more torque compared to when only one of the homopolar generator 40620 and the bipolar generator 40630 is used to power the motor 40650.

In addition to the above, other embodiments are contemplated in which the monopolar generator 40620 is configured to power only the motor 40650 and the bipolar generator 40630 is configured to charge the battery 40640, which then provides additional power to the motor 40650 (i.e., the monopolar generator 40620 does not charge the battery 40640). Furthermore, other embodiments are contemplated in which, for example, both the monopolar generator 40620 and the bipolar generator 40630 are used to simply charge the battery 40640, which then provides power to the motor 40650. In such a configuration, both the monopolar generator 40620 and the bipolar generator 40630 are synchronized to charge the battery 40640 in unison, which is then used to operate the motor 40650. In at least one embodiment, two or more motors may be utilized to drive the end effector 40611 of the surgical instrument 40610. In such a configuration, the homopolar generator 40620 can power one of the motors, and the bipolar generator 40630 can power the other motor. Furthermore, both the homopolar generator 40620 and the bipolar generator 40630 can be used to charge the battery 40640, which can then be used to power the motor. However, other embodiments are envisioned in which only one of the homopolar generator 40620 and the bipolar generator 40630 is used to charge the battery 40640.

Various aspects of the subject matter described herein are illustrated in the following set of 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 jaw and the second jaw is movable from an open position to a closed position relative to the other of the first jaw and the second jaw to grasp tissue between the first jaw and the second jaw. The second jaw includes a second electrode and a monopolar electrode centrally disposed down the length of the end effector. The first electrode and the second electrode cooperate to deliver bipolar energy to tissue in bipolar cycles. The monopolar electrode includes a wedge shape. The wedge shape has a gradually varying width along the length of the end effector. The monopolar electrode is electrically insulated from the first electrode and the second electrode. The monopolar electrode is configured to use monopolar energy to cut tissue in monopolar cycles.

Example 2 - A surgical instrument as described in Example 1, wherein the first jaw and the second jaw are laterally curved.

Example 3 - A surgical instrument as described in Example 1 or 2, wherein a monopolar cycle is performed after a bipolar cycle.

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

Example 5 - A surgical instrument described in Example 1 or 2, wherein the monopolar cycle and the bipolar cycle are operated asynchronously in the tissue treatment cycle.

Example 6 - A surgical instrument described in Examples 1, 2, 3, or 4, wherein a monopolar cycle is initiated after the start of a bipolar cycle in a tissue treatment cycle and before the end of the bipolar cycle.

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 jaw and the second jaw is movable from an open position to a closed position relative to the other of the first jaw and the second jaw to grasp tissue between the first jaw and the second jaw. The second jaw includes a second electrode and a monopolar electrode electrically isolated from the first electrode and the second electrode. The first electrode and the second electrode cooperate to deliver bipolar energy to the tissue in a bipolar cycle. The monopolar electrode includes a flexible flex circuit board centrally disposed down the length of the end effector and a conductive member disposed on the flexible flex circuit board. The monopolar electrode is configured to use monopolar energy to cut tissue in a monopolar cycle.

Example 8 - A surgical instrument as described in Example 1, wherein the seventh jaw and the second jaw are laterally curved.

Example 9 - A surgical instrument described in Example 7 or 8, wherein a monopolar cycle is performed after a bipolar cycle.

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

Example 11 - A surgical instrument described in Example 7 or 8, wherein the monopolar cycle and the bipolar cycle are operated asynchronously.

Example 12 - A surgical instrument described in Examples 7, 8, 9, or 10, wherein a monopolar cycle is initiated after the start of a bipolar cycle in a tissue treatment cycle and before the end of the bipolar cycle.

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 jaw and the second jaw is movable from an open position to a closed position relative to the other of the first jaw and the second jaw to grasp tissue between the first jaw and the second jaw. The second jaw includes a second electrode and a monopolar electrode centrally disposed down the length of the end effector. The first electrode and the second electrode cooperate to deliver bipolar energy to the tissue in a bipolar cycle. The monopolar electrode includes a conductive wire electrically insulated from the first electrode and the second electrode. The monopolar electrode is configured to use monopolar energy to cut tissue in a monopolar cycle.

Example 14 - A surgical instrument as described in Example 13, wherein a monopolar cycle is performed after a bipolar cycle.

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

Example 16 - A surgical instrument described in Examples 13, 14, or 15, wherein the conductive wire includes a flexible central portion.

Example 17 - The surgical instrument of Examples 13, 14, 15, or 16, further comprising a flexible member, wherein the conductive wire is electrically insulated from the second jaw by the flexible member.

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

Example 19 - A surgical instrument described in Example 17 or 18, wherein the flexible member is compressible.

Example 20 - The surgical instrument of Example 17, 18, or 19, wherein the flexible member includes a first flexible member, the first jaw includes a second flexible member, and the first flexible member and the second flexible member electrically insulate the conductive wire from the first jaw and the second jaw.

Example 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 end and the distal end. The first jaw is longitudinally bisected by the central plane. 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 longitudinally bisected by the central plane. 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 between the first jaw and the second jaw. The second jaw includes a second electrode and a flexible substrate. The second electrode extends along a portion of the second jaw. The second electrode is positioned on a second side of the central plane. The first electrode and the second electrode are configured to cooperate to deliver bipolar energy to tissue. A flexible substrate extends along the length of the second jaw. The flexible substrate includes a first flexible portion on a first side of a central plane, a second flexible portion on a second side of the central plane, and a monopolar electrode extending along the central plane. The second electrode is mounted on the second flexible portion. The monopolar electrode is mounted on the flexible substrate. The monopolar electrode is configured to deliver monopolar energy to tissue. The flexible 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 - A surgical end effector as described in Example 1, wherein the first flexible portion is smaller than the second flexible portion.

Example 3 - A surgical end effector as described in Example 1 or 2, wherein the second jaw includes a dielectric coating.

Example 4 - A surgical end effector as described in Example 3, wherein the flexible substrate and the dielectric coating define a coplanar tissue contacting surface.

Example 5 - A surgical end effector as described in Example 3 or 4, wherein a flexible substrate separates the dielectric coating from the monopolar electrode and the second electrode.

Example 6 - A surgical end effector described in Examples 1, 2, 3, 4, or 5, wherein the flexible substrate comprises a porous structure.

Example 7 - A surgical end effector described in Examples 1, 2, 3, 4, 5, or 6, wherein the flexible 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 includes a first porous skeleton and a first diamond-like coating at least partially covering the first porous skeleton, and 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 skeleton and a second diamond-like coating at least partially covering the second porous skeleton, and the flexible 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. A central plane of the end effector extends through the proximal end and the distal end. The first jaw is longitudinally bisected by the central plane. 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 longitudinally bisected by the central plane. 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, grasping tissue between the first jaw and the second jaw. The second jaw includes a second electrode and a compressible support. The second electrode extends along a portion of the second jaw. The second electrode is positioned on a second side of the central plane. The first electrode and the second electrode are configured to cooperate to deliver bipolar energy to tissue. The compressible support extends along the length of the second jaw. The compressible support includes a first compressible portion on a first side of a central plane, a second compressible portion on a second side of the central plane, and a monopolar electrode extending along the central plane. The second electrode is mounted on the second compressible portion. The monopolar electrode is mounted on the compressible support. The monopolar electrode is configured to deliver monopolar energy to tissue. The compressible support is configured to apply a spring bias to the second electrode and the monopolar electrode relative to 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 - A surgical instrument described in Example 10 or 11, wherein the second jaw comprises a dielectric coating.

Example 13 - A surgical instrument as described in Example 12, wherein the compressible support and the dielectric coating define a coplanar tissue-contacting surface.

Example 14 - A surgical instrument described in Example 12 or 13, wherein a compressible support separates the dielectric coating from the monopolar electrode and the second electrode.

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

Example 16 - A surgical instrument described in Examples 10, 11, 12, 13, 14, or 15, wherein the compressible support comprises a resilient honeycomb 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 skeleton and a first diamond-like coating at least partially covering the first porous skeleton, and the first electrode is disposed on the first diamond-like coating.

Example 18 - The surgical instrument of Example 10, 11, 12, 13, 14, 15, 16, or 17, wherein the second jaw further comprises a second porous skeleton and a second diamond-like coating at least partially covering the second porous skeleton, and 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 the proximal and distal ends. The first jaw includes a first electrode extending longitudinally along a portion of the first jaw. The second jaw extends longitudinally between the proximal and distal ends. At least one of the first and second jaws is movable to transition the end effector from an open configuration to a closed configuration, grasping tissue between the first and second jaws. The second jaw includes a second electrode, a monopolar electrode, and a flexible substrate. The 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 parallel to the second electrode. The monopolar electrode is configured to deliver monopolar energy to tissue. The monopolar electrode and the second electrode are fixedly mounted in a spaced-apart arrangement on a flexible substrate. The flexible 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 includes 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 wiring circuitry. The housing includes a printed control board. The wiring circuitry extends from the printed control board through the shaft and into the end effector. The wiring circuitry is configured to monitor function of the end effector and communicate the monitored function to the printed control board. The wiring circuitry 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.

Example 2 - An electrosurgical instrument as described in Example 1, wherein the resilient portion comprises a first substrate and the stretchable portion comprises a second substrate, and the first substrate and second substrate are different.

Example 3 - An electrosurgical instrument as described in Example 1 or 2, wherein the stretchable portion includes conductors in a zigzag configuration, and the conductors are made of a non-stretchable metallic material.

Example 4 - An electrosurgical instrument as described in Example 1, 2, or 3, wherein the stretchable portion includes a bellows-shaped conductor, and the conductor is made of a non-stretchable metallic material.

Example 5 - An electrosurgical instrument described in Example 1, 2, 3, or 4, wherein the resilient portion comprises a laminate 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 wiring circuitry. The housing includes a printed control board. The wiring circuitry extends from the printed control board through the shaft and into the end effector. The wiring circuitry is configured to monitor function of the end effector and communicate the monitored function to the printed control board. The wiring circuitry includes a rigid portion, a resilient portion transitionable between a relaxed configuration and an unrelaxed configuration, and a conductive wire extending through the resilient portion. The conductive wire includes a stretchable portion. The conductive wire is configured to elongate when the resilient portion transitions from the relaxed configuration to the unrelaxed configuration.

Example 7 - An electrosurgical instrument as described in Example 6, wherein the elastic portion comprises a zigzag pattern.

Example 8 - An electrosurgical instrument as described in Example 6 or 7, wherein the stretchable portion comprises a vibration pattern.

Example 9 - An electrosurgical instrument described in Examples 6, 7, or 8, wherein the elastic portion comprises a bellows shape.

Example 10 - An electrosurgical instrument described in 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 translation member configured to translate relative to the shaft to perform an end effector function; and a wiring harness. The housing includes a printed control board. The wiring harness extends from the printed control board into the shaft. The wiring harness includes a rigid body portion secured to the shaft, a resilient portion extending from the rigid body portion, and conductive wires extending through the rigid body portion and the resilient portion. An end of the resilient portion is attached to the translation member. The end of the resilient portion attached to the translation member includes a sensor configured to measure an attribute of the translation member.

Example 12 - The electrosurgical instrument of Example 11, wherein the attribute of the translation member includes a stress within the translation member.

Example 13 - The electrosurgical instrument of Example 11, wherein the attribute of the translational member includes strain within the translational member.

Example 14 - The electrosurgical instrument of Example 11, wherein the attributes of the translation member include stress and strain within the translation member.

Example 15 - An electrosurgical instrument as described in Examples 11, 12, 13, or 14, wherein the attribute of the translational member includes one of the group consisting of a position of the translational member, a velocity of the translational member, and an acceleration of the translational member.

Example 16 - An electrosurgical instrument as described in Examples 11, 12, 13, 14, or 15, wherein a portion of the conductive wire positioned within the elastic portion of the wiring harness includes a stretchable portion.

Example 17 - An electrosurgical instrument as described in Example 16, wherein the elastic portion comprises a zigzag pattern.

Example 18 - An electrosurgical instrument as described in Example 16 or 17, wherein the stretchable portion comprises a vibration pattern.

Example 19 - An electrosurgical instrument described in Example 16, 17, or 18, wherein the elastic portion comprises a bellows shape.

Example 20 - An electrosurgical instrument as described in Examples 11, 12, 13, 14, 15, 16, 17, 18, or 19, wherein the wiring harness extends into the end effector and includes a second sensor configured to measure end effector function.

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 rotational 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 operate 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 rotational drive member is operatively responsive to the motor. The rotational drive member is operatively 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 rotational drive member is actuated, the distal head rotates about the shaft axis relative to the shaft. When the distal head locking member is in the second position and the rotational drive member is actuated, the end effector moves from the open configuration toward the closed configuration.

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

Example 3 - A surgical instrument as described in Example 1 or 2, wherein when the motor is in a first operating mode, the motor is configured to rotate the rotary drive member at a first speed, and when the motor is in a second operating mode, the motor is configured to rotate the rotary drive member at a second speed, the first speed and the second speed being different.

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

Example 5 - A surgical instrument as described in Examples 1, 2, 3, or 4, wherein when the motor is in a first operating mode, the rotary drive member accelerates at a first speed, and when the motor is in a second operating mode, the rotary drive member accelerates at a second speed, the first speed and the second speed being different.

Example 6 - The surgical instrument of Examples 1, 2, 3, 4, or 5, further comprising a tensioning cable operably engaged with the distal head locking member, the tensioning cable 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 operate the motor in a first operating mode and a second operating mode. 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 operatively responsive to the motor. The rotary drive member is operatively engaged with the end effector and configured to selectively perform the first end effector function and the second end effector function. The mode selector member is operatively 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 operate in a first mode of operation when the mode selector member is in the first position. The motor is configured to operate 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 when the motor is in a first operating mode, the motor is configured to rotate the rotary drive member at a first speed, and when the motor is in a second operating mode, the motor is configured to rotate the rotary drive member at a second speed, the first speed and the second speed being different.

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

Example 10 - A surgical instrument as described in Examples 7, 8, or 9, wherein when the motor is in a first operating mode, the rotary drive member accelerates at a first speed, and when the motor is in a second operating mode, the rotary drive member accelerates at a second speed, the first speed and the second speed being different.

Example 11 - A surgical instrument comprising: a motor; a shaft defining a shaft axis; an end effector extending from the shaft; a rotational drive member operatively responsive to the motor; a locking member operatively engaged with the rotational drive member; and a toggle member operatively engaged with the locking member. The rotational drive member operatively engages 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 toggle member is rotatable about the shaft axis to move the locking member between the first and second positions. The rotational drive member is configured to perform the first end effector function when the locking member is in the first position. The rotational drive member is configured to perform the second end effector function when the locking member is in the second position.

Example 12 - A surgical instrument as described in Example 11, wherein the first end effector function includes rotating the end effector about a shaft axis and the second end effector function includes actuating a pair of jaws of the end effector.

Example 13 - The surgical instrument of Example 11, wherein the first end effector function includes translating a firing member through the end effector and the second end effector function includes 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 includes 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 operating mode and a second operating mode different from the first operating mode.

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 when the motor is in a first operating mode, the motor is configured to rotate the rotary drive member at a first speed, and when the motor is in a second operating mode, the motor is configured to rotate the rotary drive member at a second speed, the first speed and the second speed being different.

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

Example 19 - A surgical instrument as described in Examples 16, 17, or 18, wherein when the motor is in a first operating mode, the rotary drive member accelerates at a first speed, and when the motor is in a second operating mode, the rotary drive member accelerates at a second speed, the first speed and the second speed being different.

Example 20 - The surgical instrument of Examples 11, 12, 13, 14, 15, 16, 17, 18, or 19, further comprising a tensioning cable operatively engaged with the locking member and the end effector, the tensioning cable 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 comprises a housing, a shaft extending from the housing, an end effector extending from the shaft, and an internal battery in electrical communication with the generator. The housing includes an electric motor. The shaft defines a longitudinal shaft axis. The end effector is operatively 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 transverse to the longitudinal shaft axis. The generator is unable to directly provide sufficient power to the electric motor to operate the electric motor. The internal battery is configured to provide power to the electric motor. The internal battery is rechargeable by the generator to a threshold value at a charge rate that depends on the charge level of the internal battery. The charge rate is independent of charge consumption by the surgical instrument.

Example 2 - A surgical system as described in Example 1, wherein the generator is configured to charge the internal battery during charge consumption.

Example 3 - A surgical system as described in Example 1 or 2, wherein the generator supplies power to the internal battery at a constant rate when the charge level of the internal battery is below a threshold while the electric motor is drawing power from the internal battery.

Example 4 - A surgical system as described in Examples 1, 2, or 3, wherein the speed of the electric motor is capable of reaching a maximum speed when the charge level of the internal battery exceeds a predetermined minimum level.

Example 5 - A surgical system as described in Example 4, wherein the speed of the electric motor is limited to a reduced speed when the charge level of the internal battery falls below a predetermined minimum level.

Example 6 - A surgical instrument according to Examples 1, 2, 3, 4, or 5, wherein the end effector includes a first jaw including an electrode and a second jaw, and the generator is configured to supply a first power to the surgical instrument to cause the electrode to cauterize tissue captured between the first and second jaws, and to supply a second power to the surgical instrument to charge an internal battery.

Example 7 - A surgical instrument described in Examples 1, 2, 3, 4, 5, or 6, wherein the internal battery comprises a rechargeable battery.

Example 8 - A surgical instrument as described in Example 7, wherein the rechargeable battery is integrated into 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 comprises a housing, a shaft extending from the housing, an end effector extending from the shaft, and an internal battery. 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 battery is in electrical communication with the power source. The internal battery is configured to provide power to the electric motor. The internal battery is rechargeable by the power source to a threshold value at a charge rate that depends on the charge level of the internal battery. The internal battery is rechargeable 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 battery, wherein upon detecting a drop in the charge level to or below a first minimum charge level, the control circuit reduces the maximum speed limit of the electric motor to a first minimum speed limit threshold.

Example 11 - A surgical system as described in Example 10, wherein detecting a drop in charge level to or below a second minimum charge level that is lower than the first minimum charge level causes the control circuit to reduce the maximum speed limit of the electric motor to a second minimum speed limit threshold that is lower than the first minimum speed limit threshold.

Example 12 - A surgical system as described in Example 11, wherein the control circuit stops the electric motor upon detecting a drop in charge level to or below a third minimum charge level that is lower than the second minimum charge level.

Example 13 - A surgical system as described in Example 12, wherein the control circuit is configured to prevent the electric motor from re-activating until the charge level of the internal battery is equal to or greater than a third minimum charge level.

Example 14 - A surgical system described in Examples 9, 10, 11, 12, or 13, wherein the power supply supplies power to the internal battery at a constant rate when the charge level of the internal battery is below a threshold while the electric motor is drawing power from the internal battery.

Example 15 - A surgical instrument according to Examples 9, 10, 11, 12, 13, or 14, wherein the end effector includes a first jaw including an electrode and a second jaw, and is configured to supply a first power to the surgical instrument to cause the electrode to cauterize tissue captured between the first and second jaws, and to supply a second power to the surgical instrument to charge an internal battery.

Example 16 - A surgical instrument described in Examples 9, 10, 11, 12, 13, 14, or 15, wherein the internal battery comprises a rechargeable battery.

Example 17 - A surgical instrument described in Examples 9, 10, 11, 12, 13, 14, 15, or 16, wherein the power source comprises a disposable battery.

Example 18 - A surgical instrument 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 storage battery connected to the electric motor. The electric motor is configured to cause the end effector to perform an end effector function. The power supply assembly is connectable to two separate power sources. The power supply assembly is configured to separately receive first and second power sources from the power sources. The power supply assembly is configured to transmit the second power source to the internal storage battery. The power supply assembly is configured to transmit the first power source to the electric motor and the internal storage battery. The power supply assembly is configured such that the electric motor is simultaneously powered by the internal storage battery and the first power source.

Example 19 - A surgical instrument as described in Example 18, wherein the internal battery and the first power are configured to cause the electric motor to generate a first motor torque greater than a second motor torque caused by either the internal battery or the first power alone.

Example 20 - A surgical instrument described in Example 18 or 19, wherein the internal battery comprises a rechargeable battery.

While several embodiments have been shown and described, it is not the applicant's intention to restrict or limit the scope of the appended claims to such details. Numerous modifications, variations, changes, substitutions, combinations, and equivalents of these embodiments may be implemented and will occur to those skilled in the art without departing from the scope of the present disclosure. Moreover, the structure of each element associated with the described embodiments can alternatively be described as a means for providing the function performed by that element. Also, while materials are disclosed with respect to particular components, other materials may be used. It is therefore to be understood that the above description and the appended claims are intended to cover all such modifications, combinations, and variations as fall within the scope of the disclosed embodiments. The appended claims are intended to cover all such modifications, variations, changes, substitutions, modifications, and equivalents.

The above detailed description has set forth various aspects of the devices and/or processes via the use of block diagrams, flow diagrams, and/or examples. To the extent that such block diagrams, flow diagrams, and/or examples include one or more functions and/or operations, it will be understood by those skilled in the art that each function and/or operation included in such block diagrams, flow diagrams, and/or examples can be implemented individually and/or collectively by various types of hardware, software, firmware, or virtually any combination thereof. Those skilled in the art will understand that some aspects of the embodiments disclosed herein may be equivalently implemented, in whole or in part, 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 on an integrated circuit, as substantially any combination thereof, and that designing circuitry and/or writing software and/or firmware code is within the skill of those skilled in the art in light of this disclosure. Additionally, those skilled in the art will understand that the subject mechanisms described herein can be distributed as one or more program products in a variety of forms, and that the specific embodiments of the subject matter described herein apply regardless of the particular type of signal-bearing medium used to actually effect the distribution.

The instructions used to program the logic to implement various disclosed aspects may be stored in system memory, such as dynamic random access memory (DRAM), cache, flash memory, or other storage. Additionally, the instructions may be distributed over a network or by other computer-readable media. Thus, machine-readable media may include any mechanism for storing or transmitting information in a form readable by a machine (e.g., a computer), including, but not limited to, floppy diskettes, optical disks, compact disks, read-only memories (CD-ROMs), 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 memories, or tangible machine-readable storage used to transmit information over the Internet via electrical, optical, acoustic, or other forms of propagated signals (e.g., carrier waves, infrared signals, digital signals, etc.). Accordingly, non-transitory computer-readable media 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 of this specification, the term "control circuitry" may refer to, for example, hardwired circuitry, programmable circuitry (e.g., a computer processor including one or more individual instruction processing cores, a processing unit, a processor, a microcontroller, a microcontroller unit, a controller, a digital signal processor (DSP), a programmable logic device (PLD), a programmable logic array (PLA), or a field programmable gate array (FPGA)), a state machine circuit, firmware that stores instructions executed by the programmable circuitry, and any combination thereof. Control circuitry may be embodied, collectively or individually, as circuits that form part of a larger system, such as, for example, an integrated circuit (IC), an application-specific integrated circuit (ASIC), a system-on-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, electrical circuitry having at least one discrete electrical circuit, electrical circuitry having at least one integrated circuit, electrical circuitry having at least one application-specific integrated circuit, electrical circuitry forming a general-purpose computing device configured by a computer program (e.g., a general-purpose computer configured by a computer program that at least partially executes the processes and/or apparatus described herein, or a microprocessor configured by a computer program that at least partially executes the processes and/or apparatus described herein), electrical circuitry forming a memory device (e.g., a form of random access memory), and/or electrical circuitry forming a communications device (e.g., a modem, a communications switch, or an optical-to-electrical facility). Those skilled in the art will recognize that the subject matter described herein may be implemented in analog or digital form, or some combination thereof.

As used in any aspect of this specification, the term "logic" may refer to an application, software, firmware, and/or circuitry configured to perform any of the operations described above. 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 in a memory device, and/or hard-coded (e.g., non-volatile) data.

When used in any aspect of this specification, the terms "component," "system," "module," etc. may refer to a computer-related entity that is either hardware, a combination of hardware and software, software, or software in execution.

As used in any aspect of this specification, an "algorithm" refers to a self-consistent sequence of steps leading to a desired result, and the "steps" refer to manipulations of physical quantities and/or logical states, which may, but need not, take the form of electrical or magnetic signals capable of being stored, transferred, combined, compared, and otherwise manipulated. It is common practice 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 or are merely convenient labels applied to these quantities and/or states.

The network may include a packet-switched network. The communication devices may communicate with each other using a selected packet-switched network communication protocol. One exemplary communication protocol may include an Ethernet communication protocol, which may enable communication using 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," published December 2008, by the Institute of Electrical and Electronics Engineers (IEEE), and/or later versions of this standard. Alternatively or additionally, the communication devices may communicate with each other using the X.25 communication protocol. The T.25 communication protocol may conform to or be compatible with standards promulgated by the International Telecommunication Union-Telecommunication Standards Sector (ITU-T). Alternatively or additionally, the communication devices may communicate 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 Consultative Committee for International Telegraph and Telephone (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 communication protocol may conform to or be compatible with the ATM standard published by the ATM Forum in August 2001, entitled "ATM-MPLS Network Interworking 2.0," and/or later versions of this standard. Of course, different and/or later-developed connection-oriented network communication protocols are equally contemplated herein.

Unless expressly specified otherwise, as will be apparent from the foregoing disclosure, discussions throughout the foregoing disclosure using terms such as "processing," "computing," "calculating," "determining," "displaying," and the like will be understood to refer to the actions and processing of a computer system or similar electronic computing device that manipulates and transforms data represented as physical (electronic) quantities in the computer system's registers and memory into other data similarly represented as physical quantities in the computer system's memory or registers or other such information storage, transmission, or display device.

One or more components may be referred to herein as being "configured to," "configurable to," "operable/operative to," "adapted/adaptable," "able to," "conformable/conformed to," etc. Those skilled in the art will understand that "configured to" may generally encompass active components and/or inactive components and/or standby components, unless the context requires otherwise.

The terms "proximal" and "distal" are used herein with reference to a clinician manipulating the 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 understood that for convenience and clarity, spatial terms such as "vertical," "horizontal," "above," and "below" 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 understand that the terms used herein generally, and in the appended claims in particular (e.g., the body 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.). Furthermore, those skilled in the art will understand that where a specific number is intended in an introduced claim recitation, such intention will be clearly stated in the claim; and, in the absence of such a statement, no such intention exists. For example, as an aid to understanding, the appended claims below may include the introductory phrases "at least one" and "one or more" to introduce the claim recitation. However, the use of such phrases should not be construed as suggesting that when a claim is introduced by the indefinite article "a" or "an," any particular claim containing such introduced claim language is limited to claims containing only one such recitation, even if the same claim contains an introductory phrase such as "one or more" or "at least one" and the indefinite article "a" or "an" (e.g., "a" and/or "an" should normally be construed to mean "at least one" or "one or more"). The same applies when a definite article is used to introduce a claim.

Additionally, those skilled in the art will recognize that even when a specific number is explicitly stated in an introduced claim, such a statement should typically be interpreted to mean at least the recited number (e.g., a statement simply stating "two items" without other modifiers generally means at least two items, or two or more items). Furthermore, when a term similar to "at least one of A, B, and C, etc." is used, such syntax is generally intended to mean what a person skilled in the art would understand the term (e.g., "a system having at least one of A, B, and C" includes, but is not limited to, systems having only A, only B, only C, both A and B, both A and C, both B and C, and/or all of A, B, and C, etc.). When notation similar to "at least one of A, B, or C, etc." is used, such syntax is generally intended in the sense that one of ordinary skill in the art would understand the notation (e.g., "a system having at least one of A, B, or C" includes, but is not limited to, systems having only A, only B, only C, both A and B, both A and C, both B and C, and/or all of A, B, and C, etc.). Furthermore, one of ordinary skill in the art will understand that any disjunctive word and/or phrase expressing two or more alternative terms should typically be understood to contemplate the possibility of including one of those terms, either of those terms, or both of those terms, unless the context requires otherwise, whether in the specification, claims, or drawings. For example, the phrase "A or B" will typically be understood to include the possibilities of "A" or "B" or "A and B."

With respect to the appended claims, those skilled in the art will understand that the recited actions herein generally may be performed in any order. Additionally, while flow diagrams of various actions are shown in a sequence, it should be understood that the various actions may be performed in orders other than those shown, or may be performed simultaneously. Examples of such alternative orderings may include overlapping, interleaved, interrupted, reordered, incremental, preliminary, additional, simultaneous, reverse, or other different orderings, unless the context requires otherwise. Furthermore, terms such as "responsive to," "related to," or other past-tense adjectives are generally not intended to exclude such variations, unless the context requires otherwise.

It is worth noting that any reference to "one embodiment," "embodiment," "exemplary," "one example," etc. means that a particular feature, structure, or characteristic described in connection with that embodiment is included in at least one embodiment. Thus, the appearances of the phrases "in one embodiment," "in an embodiment," "exemplary," and "in one example" in various places throughout this specification do not necessarily all refer to the same embodiment. Furthermore, particular features, structures, or characteristics may be combined in any suitable manner in one or more embodiments.

As used herein, unless otherwise indicated, the terms "about" or "approximately" as used in this disclosure refer to an acceptable error for a particular value as determined by one of ordinary skill in the art, which depends in part on how the value is measured or determined. In certain embodiments, the terms "about" or "approximately" mean within 1, 2, 3, or 4 standard deviations. In certain embodiments, the terms "about" or "approximately" mean 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 this specification, unless otherwise indicated, all numerical parameters should be understood in all instances to be preceded and modified by the term "about," given the inherent variability of the underlying measurement methods used to determine the numerical value of such parameters. At the very least, no attempt should be made to limit the application of the doctrine of equivalents to the scope of the claims, and each numerical parameter set forth 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 subranges subsumed within the recited range. For example, a range of "1 to 10" includes all subranges between (and including) the recited minimum of 1 and the recited maximum of 10, i.e., all subranges having a minimum of 1 or more and a maximum of 10 or less. Also, all ranges recited herein include the recited endpoints. For example, a range of "1 to 10" includes the endpoints 1 and 10. Every maximum numerical limit recited herein is intended to include all subsumed lower numerical limits, and every minimum numerical limit recited herein is intended to include all subsumed higher numerical limits. Accordingly, applicants reserve the right to amend this specification, including the claims, to include all explicitly recited subranges that fall within the explicitly recited ranges. All such ranges are inherently recited herein.

Any patent application, patent, non-patent publication, or other disclosure material referenced herein and/or listed in any Application Data Sheet is incorporated herein by reference to the extent the incorporated material is not inconsistent with this specification. As such, and to the extent necessary, the disclosure material explicitly set forth in this specification shall supersede any conflicting statements incorporated herein by reference. Any material, or portions thereof, that is said to be incorporated herein by reference but that conflicts with current definitions, views, or other disclosure material set forth herein shall be incorporated only to the extent that no conflict arises between the incorporated material and the current disclosure material.

In summary, many benefits have been described that result from using the concepts described herein. The foregoing description of one or more embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or to be limited to the precise form disclosed. Modifications or variations are possible in light of the above teachings. The one or more embodiments have been selected and described to illustrate the principles and practical applications, thereby enabling those skilled in the art to utilize various embodiments, with various modifications, as suited to the particular use contemplated. It is intended that the claims presented herewith define the overall scope.

[Embodiment]
(1) A surgical system, comprising:
A generator;
a surgical instrument configured to receive power from the generator, the surgical instrument comprising:
a housing including an electric motor;
a shaft extending from the housing, the shaft defining a longitudinal shaft axis;
an end effector extending from the shaft and operatively responsive to actuation from the electric motor, the end effector being transitionable between an open configuration and a closed configuration, the end effector being rotatable relative to the longitudinal shaft axis about an articulation axis transverse to the longitudinal shaft axis, and the generator not being capable of directly supplying sufficient power to the electric motor to cause it to perform the actuation;
an internal battery in electrical communication with the generator, the internal battery configured to power the electric motor, the internal battery chargeable by the generator to a threshold value at a charge rate dependent on a charge level of the internal battery, the charge rate being independent of charge consumption by the surgical instrument.
(2) The surgical system according to claim 1, wherein the generator is configured to charge the internal battery during the charge consumption.
3. The surgical system of claim 1, wherein the generator supplies power to the internal battery at a constant rate when the charge level of the internal battery is below the threshold while the electric motor is drawing power from the internal battery.
(4) The surgical system according to claim 1, wherein the speed of the electric motor is capable of reaching a maximum speed when the charge level of the internal battery exceeds a predetermined minimum level.
5. The surgical system of claim 4, wherein the speed of the electric motor is limited to a reduced speed when the charge level of the internal battery falls below the predetermined minimum level.

6. The surgical instrument of claim 1, wherein the end effector includes a first jaw including an electrode and a second jaw, and the generator is configured to supply a first power to the surgical instrument to cause the electrode to cauterize tissue captured between the first and second jaws and a second power to the surgical instrument to charge the internal battery.
7. The surgical instrument of claim 1, wherein the internal battery comprises a rechargeable battery.
8. The surgical instrument of claim 7, wherein the rechargeable battery is integral with the housing.
(9) A surgical system, comprising:
Power supply and
a surgical instrument configured to receive power from the power source, the surgical instrument comprising:
a housing including an electric motor;
a shaft extending from the housing;
an end effector extending from the shaft, the end effector operably coupled to the electric motor, the electric motor configured to drive the end effector to perform an end effector function; and
an internal battery in electrical communication with the power source, the internal battery configured to power the electric motor, the internal battery being chargeable by the power source to a threshold value at a charge rate dependent on a charge level of the internal battery, the internal battery being chargeable by the power source while the electric motor drives the end effector to perform the end effector function.
10. The surgical system of claim 9, further comprising a control circuit configured to detect the charge level of the internal battery, wherein detecting a drop in the charge level to or below a first minimum charge level causes the control circuit to reduce a maximum speed limit of the electric motor to a first minimum speed limit threshold.

11. The surgical system of claim 10, wherein detecting a drop in the charge level to or below a second minimum charge level that is lower than the first minimum charge level causes the control circuit to reduce a maximum speed limit of the electric motor to a second minimum speed limit threshold that is lower than the first minimum speed limit threshold.
12. The surgical system of claim 11, wherein detecting a drop in the charge level to or below a third minimum charge level that is lower than the second minimum charge level causes the control circuit to stop the electric motor.
13. The surgical system of claim 12, wherein the control circuit is configured to prevent reactivation of the electric motor until the charge level of the internal battery is equal to or greater than the third minimum charge level.
14. The surgical system of claim 9, wherein the power source supplies power to the internal battery at a constant rate when the charge level of the internal battery is below the threshold while the electric motor is drawing power from the internal battery.
15. The surgical instrument of claim 9, wherein the end effector includes a first jaw including an electrode and a second jaw, and 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, and a second power to the surgical instrument to charge the internal battery.

16. The surgical instrument of claim 9, wherein the internal battery comprises a rechargeable battery.
17. The surgical instrument of claim 15, wherein the power source is a disposable battery.
(18) A surgical instrument,
A housing,
An electric motor;
an internal battery connected to the electric motor; and
a shaft extending from the housing;
an end effector extending from the shaft, the electric motor configured to cause the end effector to perform an end effector function;
1. A surgical instrument comprising: a power supply assembly connectable to two separate power sources, the power supply assembly configured to separately receive first and second powers from the power sources, the power supply assembly configured to deliver the second power to the internal storage battery, and the power supply assembly configured to deliver the first power to the electric motor and the internal storage battery, the power supply assembly configured such that the electric motor is simultaneously powered by the internal storage battery and the first power.
19. The surgical instrument of claim 18, wherein the internal battery and the first power are configured to cause the electric motor to generate a first motor torque greater than a second motor torque caused by only one of the internal battery and the first power.
20. The surgical instrument of claim 19, wherein the internal battery comprises a rechargeable battery.

Claims (17)

1. A surgical instrument configured to receive power from a generator, the surgical instrument comprising:
a housing including an electric motor;
a shaft extending from the housing, the shaft defining a longitudinal shaft axis;
an end effector extending from the shaft and operatively responsive to actuation from the electric motor, the end effector being transitionable between an open configuration and a closed configuration, the end effector being rotatable relative to the longitudinal shaft axis about an articulation axis transverse to the longitudinal shaft axis, and the generator not being capable of directly supplying sufficient power to the electric motor to cause it to perform the actuation;
an internal battery in electrical communication with the generator, the internal battery configured to power the electric motor, the internal battery being chargeable by the generator to a threshold value at a charge rate that is dependent on a charge level of the internal battery, the charge rate being independent of charge consumption by the surgical instrument;
1. A surgical instrument, wherein the end effector includes a first jaw including an electrode and a second jaw, the surgical instrument configured to receive first power from the generator to cause the electrode to cauterize tissue captured between the first and second jaws, and to receive second power from the generator to charge the internal battery. The surgical instrument according to claim 1 , wherein the second power is configured to charge the internal storage battery during the charge consumption. 10. The surgical instrument of claim 1, wherein the internal battery receives power from the generator at a constant rate when the charge level of the internal battery is below the threshold while the electric motor is drawing power from the internal battery . The surgical instrument of claim 1, wherein the speed of the electric motor is capable of reaching a maximum speed when the charge level of the internal battery exceeds a predetermined minimum level. The surgical instrument of claim 4, wherein the speed of the electric motor is limited to a reduced speed when the charge level of the internal battery falls below the predetermined minimum level. The surgical instrument of claim 1, wherein the internal battery comprises a rechargeable battery. The surgical instrument of claim 6, wherein the rechargeable battery is integrated with the housing. 1. A surgical system comprising:
Power supply and
a surgical instrument configured to receive power from the power source, the surgical instrument comprising:
a housing including an electric motor;
a shaft extending from the housing;
an end effector extending from the shaft, the end effector operably coupled to the electric motor, the electric motor configured to drive the end effector to perform an end effector function; and
an internal battery in electrical communication with the power source, the internal battery configured to power the electric motor, the internal battery being chargeable by the power source to a threshold value at a charge rate dependent on a charge level of the internal battery, the internal battery being chargeable by the power source while the electric motor drives the end effector to perform the end effector function;
The surgical system further comprises a control circuit configured to detect the charge level of the internal battery, wherein detecting a drop in the charge level to or below a first minimum charge level causes the control circuit to reduce a maximum speed limit of the electric motor to a first minimum speed limit threshold. The surgical system of claim 8, wherein upon detecting a drop in the charge level to or below a second minimum charge level that is lower than the first minimum charge level, the control circuit reduces the maximum speed limit of the electric motor to a second minimum speed limit threshold that is lower than the first minimum speed limit threshold. The surgical system of claim 9, wherein the control circuit stops the electric motor upon detecting a drop in the charge level to or below a third minimum charge level that is lower than the second minimum charge level. The surgical system of claim 10, wherein the control circuit is configured to prevent the electric motor from re-activating until the charge level of the internal battery is equal to or greater than the third minimum charge level. The surgical system of claim 8, wherein the power supply supplies power to the internal battery at a constant rate when the charge level of the internal battery is below the threshold while the electric motor is drawing power from the internal battery. The surgical system of claim 8, wherein the internal battery comprises a rechargeable battery. 1. A surgical instrument configured to receive power from a power source, the surgical instrument comprising:
a housing including an electric motor;
a shaft extending from the housing;
an end effector extending from the shaft, the end effector operably coupled to the electric motor, the electric motor configured to drive the end effector to perform an end effector function; and
an internal battery in electrical communication with the power source, the internal battery configured to power the electric motor, the internal battery being chargeable by the power source to a threshold value at a charge rate dependent on a charge level of the internal battery, the internal battery being chargeable by the power source while the electric motor drives the end effector to perform the end effector function;
1. A surgical instrument, wherein the end effector includes a first jaw including an electrode and a second jaw, the surgical instrument configured to receive first power from the power source to cause the electrode to cauterize tissue captured between the first and second jaws, and to receive second power from the power source to charge the internal battery. 15. The surgical instrument of claim 14, wherein the internal battery receives power from the power source at a constant rate when the charge level of the internal battery is below the threshold while the electric motor is drawing power from the internal battery. The surgical instrument of claim 14, wherein the internal battery comprises a rechargeable battery. The surgical system of claim 8 , wherein the power source is a disposable battery.