Electrosurgical devices and methods of use

Abstract

In one embodiment, an electrosurgical device includes a housing having a proximal end and a distal end, an electrosurgical electrode extending distally from the distal end of the housing, a plurality of light sources in the housing, and an optical lens assembly including a plurality of optical components (i) coupled to each other at the distal end of the optical lens assembly and (ii) spaced apart from each other at the proximal end of the optical lens assembly. Each optical component includes a proximal reflective surface and a distal transmissive surface. Each proximal reflective surface extends distally from a respective light source and has an aspheric shape configured to substantially collimate light reflected by the proximal reflective surface. Each distal transmissive surface is configured to output light distally from the optical component.

Description

[Technical field]

[0001] (CROSS REFERENCE TO RELATED APPLICATIONS) This application claims the benefit of U.S. Provisional Application No. 63 / 076,089, filed September 9, 2020, and U.S. Provisional Application No. 63 / 211,876, filed June 17, 2021, the contents of which are incorporated by reference herein in their entireties.

[0002] The present disclosure relates generally to electrosurgical devices and, more particularly, to electrosurgical devices and methods for illuminating a surgical site during an electrosurgical procedure. [Background technology]

[0003] Electrosurgery involves the application of radio frequency (RF) electrical current (also referred to as electrosurgical energy) to biological tissue to cut, coagulate, or modify the tissue during an electrosurgical procedure. In particular, an electrosurgical generator generates and provides electrical current to an active electrode, which applies the current (and thus power) to the tissue. The current passes through the tissue and returns to the generator via a return electrode (also referred to as a "dispersive electrode"). As the current passes through the tissue, the impedance of the tissue converts a portion of the current into thermal energy (e.g., via the principles of resistive heating), which increases the temperature of the tissue and induces modifications to the tissue (e.g., cutting, coagulating, removing, and / or sealing the tissue). Summary of the Invention

[0004] In one embodiment, an electrosurgical device is described. The electrosurgical device includes a housing having a proximal end and a distal end. The electrosurgical device also includes an electrosurgical electrode extending distally from the distal end of the housing and a plurality of light sources within the housing. The multiple light sources can be configured to generate light.

[0005] In addition, the electrosurgical device can include an optical lens assembly having a proximal end and a distal end. The optical lens assembly can include a plurality of optical components (i) coupled to one another at the distal end of the optical lens assembly and (ii) spaced apart from one another at the proximal end of the optical lens assembly. Each optical component is optically coupled to a respective light source of the plurality of light sources. Each optical component includes a proximal reflective surface extending distally from a respective light source optically coupled to the optical component and a distal transmitting surface at the distal end of the optical lens assembly. The proximal reflective surface is configured to reflect light emitted by the respective light source toward the distal end. The proximal reflective surface can have an aspheric shape configured to substantially collimate light reflected by the proximal reflective surface. The distal transmitting surface is configured to output light distally from the optical component.

[0006] In another embodiment, a process for operating an electrosurgical device is described. The process includes providing an electrosurgical device at block 2410. The electrosurgical device can include a housing having a proximal end and a distal end. The electrosurgical device can also include an electrosurgical electrode extending distally from the distal end of the housing and a plurality of light sources in the housing. The multiple light sources can be configured to generate light.

[0007] In addition, the electrosurgical device can include an optical lens assembly having a proximal end and a distal end. The optical lens assembly can include a plurality of optical components (i) coupled to one another at the distal end of the optical lens assembly and (ii) spaced apart from one another at the proximal end of the optical lens assembly. Each optical component is optically coupled to a respective light source of the plurality of light sources. Each optical component includes a proximal reflective surface extending distally from a respective light source optically coupled to the optical component and a distal transmitting surface at the distal end of the optical lens assembly. The proximal reflective surface is configured to reflect light emitted by the respective light source toward the distal end. The proximal reflective surface can have an aspheric shape configured to substantially collimate light reflected by the proximal reflective surface. The distal transmitting surface is configured to output light distally from the optical component.

[0008] The process also includes emitting light by the multiple light sources. After emitting the light, the process includes transmitting the light through each optical component by (i) reflecting the light in a substantially collimated manner by a proximal reflective surface of the optical component toward a distal end, and (ii) outputting the light in a distal direction by a distal transmissive surface of the optical component.

[0009] The process also includes rotating the shaft relative to the housing to cause corresponding rotation of the electrosurgical electrode relative to the housing. The process further includes delivering electrosurgical energy from the shaft to the electrosurgical electrode.

[0010] The features believed to be novel features of the illustrative embodiments are set forth in the appended claims, however the illustrative embodiments, together with their preferred modes of use, further objects and explanations, will best be understood by reference to the following detailed description of illustrative embodiments of the present disclosure when read in connection with the accompanying drawings. [Brief description of the drawings]

[0011] [Figure 1]1 is a simplified block diagram of an electrosurgical system, according to one embodiment. [Diagram 2] 1 is a cross-sectional view of an electrosurgical device, according to one embodiment. [Diagram 3] 1 is a simplified block diagram of an electrosurgical device, according to one embodiment. [Figure 4A] 4 illustrates an implementation of the optical lens assembly and light source shown in FIG. 3, according to one embodiment. [Figure 4B] 5 is a cross-sectional view of optical components of the optical lens assembly shown in FIG. 4 according to one embodiment. [Figure 5A] 4 illustrates an implementation of the optical lens assembly and light source shown in FIG. 3 according to another embodiment. [Figure 5B] 6 is a cross-sectional view of optical components of the optical lens assembly shown in FIG. 5 according to one embodiment. [Figure 6] 1 is a simplified block diagram of a light source according to one embodiment. [Figure 7A] 4A-4B, showing a perspective view of an embodiment of the electrosurgical device of FIG. 1 and the optical lens assembly of FIGS. 4A-B, with the shaft in a first axial position relative to the housing, according to one embodiment. [Figure 7B] 7B is a perspective view of the embodiment of the electrosurgical device of FIG. 7A, with the shaft in a second axial position relative to the housing, according to one embodiment. [Figure 8] FIG. 8 is a partially exploded view of a housing of the electrosurgical device shown in FIGS. 7A-7B, according to one embodiment. [Figure 9] FIG. 8 is a cross-sectional view of a housing, shaft, and distal portion of an electrosurgical electrode for the example embodiment shown in FIGS. 7A-B, according to one embodiment. [Figure 10] FIG. 2 is a perspective view of an electrical contact according to an embodiment. [Figure 11] FIG. 7B illustrates a distal portion of a shaft with the upper portion removed to show optical components disposed in the inner cavity of the shaft for the example embodiment shown in FIGS. 7A-B, according to one embodiment. [Figure 12]4A-4B show an electrosurgical electrode, a suction sleeve, the optical lens assembly of FIGS. 4A-B, and a light source assembly, according to one embodiment. [Figure 13] 13 illustrates the electrosurgical device of FIGS. 7A-12 with components removed to illustrate the dynamics for providing power to the light source, according to one embodiment. FIG. [Figure 14] 5A-5B, according to another embodiment of the electrosurgical device of FIG. 1 and the optical lens assembly of FIGS. 5A-B. [Figure 15] 15 is a cross-sectional view of the electrosurgical device shown in FIG. 14 taken along a longitudinal axis of the electrosurgical device, according to an embodiment. [Figure 16] 16 is an enlarged cross-sectional view of the shaft and distal end of the electrosurgical electrode shown in FIG. 15, according to one embodiment. [Figure 17] FIG. 17 is a perspective view of the smoke evacuation channel and shaft of the electrosurgical device shown in FIGS. 14-16, according to one embodiment. [Figure 18] FIG. 17 is a side view of the smoke evacuation channel and shaft of the electrosurgical device shown in FIGS. 14-16, according to one embodiment. [Figure 19] FIG. 17 is a partially exploded view of a light source, optical lens and heat sink assembly in a smoke evacuation channel of the electrosurgical device shown in FIGS. 14-16, according to one embodiment. [Figure 20] FIG. 5C illustrates an assembly of the optical lens assembly and electrosurgical electrodes of FIGS. 5A-B, according to one embodiment. [Figure 21] 4 is a cross-sectional view of optical components of the optical lens assembly shown in FIG. 3 according to one embodiment. [Figure 22] 4B-4C show optical output patterns for the optical lens assembly shown in FIG. 4B, according to one embodiment. [Figure 23] FIG. 5C illustrates an example optical output pattern for the optical lens assembly shown in FIGS. 5A-B, according to one embodiment. [Figure 24] 1 is a flowchart of an example of a process for operating an electrosurgical device, according to one embodiment. [Diagram 25] 25 is a flow chart of an example of a process for operating an electrosurgical device that can be used with at least the process shown in FIG. 24. [Figure 26] 25 is a flow chart of an example of a process for operating an electrosurgical device that can be used with at least the process shown in FIG. 24. [Figure 27] 25 is a flow chart of an example of a process for operating an electrosurgical device that can be used with at least the process shown in FIG. 24. [Figure 28] 25 is a flow chart of an example of a process for operating an electrosurgical device that can be used with at least the process shown in FIG. 24. [Figure 29] 25 is a flow chart of an example of a process for operating an electrosurgical device that can be used with at least the process shown in FIG. 24. [Diagram 30] 25 is a flow chart of an example of a process for operating an electrosurgical device that can be used with at least the process shown in FIG. 24. [Diagram 31] 25 is a flow chart of an example of a process for operating an electrosurgical device that can be used with at least the process shown in FIG. 24. [Diagram 32] 25 is a flow chart of an example of a process for operating an electrosurgical device that can be used with at least the process shown in FIG. 24. [Diagram 33] 25 is a flow chart of an example of a process for operating an electrosurgical device that can be used with at least the process shown in FIG. 24. [Diagram 34] 25 is a flow chart of an example of a process for operating an electrosurgical device that can be used with at least the process shown in FIG. 24. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] The disclosed embodiments will now be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all, of the disclosed embodiments are shown. Indeed, several different embodiments may be described and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are described so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.

[0013] The terms "about" or "substantially" with respect to a quantity or measurement described herein mean that the cited characteristic, parameter or value need not be achieved exactly, but rather that deviations or variations including, for example, tolerances, measurement errors, measurement accuracy limits, and other factors known to those of ordinary skill in the art, may occur in an amount that does not eliminate the effect that the characteristic is intended to provide.

[0014] As described above, the electrosurgical device can use electrical energy provided by an electrosurgical generator to apply electrosurgical energy from the electrosurgical electrodes to tissue. To help the practitioner better visualize the surgical site while performing electrosurgery, the electrosurgical device can include features that provide for distal transmission of light to illuminate the surgical site. For example, the electrosurgical device can include one or more optical features that transmit light along and / or around the electrosurgical electrodes to illuminate the surgical site.

[0015] Although it may be advantageous to provide an electrosurgical device with optical features for transmitting light, the optical features occupy space in or on the electrosurgical device. This may create some challenges. For example, it may be advantageous to limit or reduce the size of the electrosurgical device to provide greater access to small surgical cavities and / or to reduce the electrosurgical device's impairment of line of sight to the electrosurgical electrodes and / or surgical site. These space constraint considerations may be more acute in embodiments in which the electrosurgical device includes other space-occupying features, such as features for evacuating surgical smoke from the surgical site.

[0016] Another challenge is to achieve quality of light emission in the relatively small space available. Indeed, it may be desirable to provide light around the electrosurgical electrodes. And it may be advantageous to do so while reducing shadows cast by the electrosurgical electrodes. Furthermore, it may be advantageous to reduce light losses along the light transmission path between the light source and the point where the light is output from the electrosurgical device. For example, reducing light losses can help reduce the power requirements to operate the light source and / or reduce heat.

[0017] The present application provides an optical lens assembly that can be incorporated into an electrosurgical device to address one or more of the problems set forth above.

[0018] Referring now to Figure 1, an electrosurgical system 100 is shown according to one embodiment. As shown in Figure 1, electrosurgical system 100 includes an electrosurgical generator 110 and an electrosurgical device 112. Generally, electrosurgical generator 110 is capable of generating electrosurgical energy suitable for performing electrosurgery on a patient. For example, electrosurgical generator 110 can include an electrode converter circuit 114 that can convert grid power into electrosurgical energy, such as, for example, radio frequency (RF) output power. As an example, power converter circuit 114 can include one or more components (e.g., one or more transformers) that can control the voltage, current and / or frequency of the electrosurgical energy.

[0019] In embodiments, electrosurgical generator 110 may include a user interface 116 that may receive one or more inputs from a user and / or provide one or more outputs to a user. By way of example, user interface 116 may include one or more buttons, one or more switches, one or more dials, one or more keypads, one or more touch screens, one or more display screens, one or more indicator lights, one or more speakers, and / or one or more tactile output devices.

[0020] In one example, the user interface 116 can be operable to select an operating mode from among a plurality of operating modes for the electrosurgical generator 110. By way of example, the operating modes can include a cutting mode, a coagulation mode, a removal mode, and / or a sealing mode. Combinations of these waveforms can also be formed to generate mixed modes. In one embodiment, the operating modes can correspond to respective waveforms for the electrosurgical energy. Thus, in this embodiment, the electrosurgical generator 110 can generate electrosurgical energy having a waveform selected from a plurality of waveforms based at least in part on the operating mode selected using the user interface 116.

[0021] Electrosurgical generator 110 may also include one or more sensors 118 capable of sensing one or more conditions associated with the electrosurgical energy and / or the target tissue. By way of example, sensors 118 may include one or more current sensors, one or more voltage sensors, one or more temperature sensors, and / or one or more bioimpedance sensors. In examples, electrosurgical generator 110 may additionally or alternatively generate a predetermined amount of electrosurgical energy (e.g., power) and / or electrosurgical energy having a waveform selected from among a plurality of waveforms based on one or more parameters associated with the condition sensed by sensor 118.

[0022] In one embodiment, the electrosurgical energy can have a frequency greater than about 100 kilohertz (kHz) to reduce (or avoid) stimulating muscles and / or nerves near the target tissue, hi another embodiment, the electrosurgical energy can have a frequency between about 300 kHz and about 500 kHz.

[0023] 1 , electrosurgical generator 110 also includes a connector 120 that can facilitate coupling of electrosurgical generator 110 to electrosurgical device 112. For example, electrosurgical device 112 can include a power cord 122 having a plug, which can couple to a socket of connector 120 of electrosurgical generator 110. In this arrangement, electrosurgical generator 110 can supply electrosurgical energy to electrosurgical device 112 via the coupling between connector 120 of electrosurgical generator 110 and power cord 122 of electrosurgical device 112.

[0024] 1, electrosurgical device 112 can include a housing 123. Housing 123 can be an elongated structure within which and / or upon which the components of electrosurgical device 112 can be disposed. In some embodiments, housing 123 can be a one-piece monolithic structure. In other embodiments, housing 123 can include multiple structures coupled together.

[0025] 1, housing 123 includes a handle 124 defining an internal bore, a shaft 126 extending distally from handle 124, and an electrosurgical electrode 128 coupled to shaft 126. Generally, handle 124 can be configured to facilitate a user grasping and manipulating electrosurgical device 112 while performing electrosurgery. For example, handle 124 can have a shape and / or size that can facilitate a user performing electrosurgery by manipulating electrosurgical device 112 using one hand. In one embodiment, handle 124 can have a shape and / or size that can facilitate a user holding electrosurgical device 122 in a pencil grip fashion (e.g., electrosurgical device 112 can be an electrosurgical pencil).

[0026] Additionally, for example, the handle 124 and / or shaft 126 can be constructed from one or more materials that are electrical insulators (e.g., plastic materials), which can facilitate isolating the user from the electrosurgical energy flowing through the electrosurgical device 112 while performing electrosurgery.

[0027] In some embodiments, the shaft 126 can be coupled to the handle 124 in a fixed, immovable manner. This may simplify manufacturing and reduce manufacturing costs, for example, by simplifying electrical connections that may otherwise be required to compensate for movement of the shaft 126 and handle 124 relative to one another (e.g., by eliminating slip ring electrical contacts and / or sliding electrical contacts). In one example, the handle 124 and shaft 126 can be formed as a single monolithic structure such that the shaft 126 and handle 124 are fixed and immovable relative to one another. In another example, the handle 124 and shaft 126 can be fixedly coupled to one another by a welded bond, an adhesive bond, and / or another bond that prevents movement between the handle 124 and shaft 126.

[0028] In other embodiments, the shaft 126 can be telescopically movable relative to the handle 124. For example, the shaft 126 can be telescopically movable (e.g., movable along the longitudinal axis of the electrosurgical device 112) in an internal bore defined by the handle 124 to extend the shaft 126 distally and retract the shaft 126 proximally relative to the handle 124. In some embodiments, an electrosurgical electrode 128 is coupled to the shaft 126 such that the electrosurgical electrode 128, together with the shaft 126, can move axially along the longitudinal axis relative to the handle 124. This can provide adjustment of the length of the electrosurgical device 112, which can facilitate performing electrosurgery at different depths within tissue (e.g., due to different anatomical shapes and / or sizes of the patient) and / or at different angles.

[0029] In some embodiments, electrosurgical electrode 128 can additionally or alternatively be rotatable about an axis of rotation parallel to the longitudinal axis of electrosurgical device 112. In some embodiments, electrosurgical electrode 128 can be rotatable relative to handle 124 and shaft 126. In other embodiments, electrosurgical electrode 128 can be rotationally fixed relative to shaft 126 such that shaft 126 and electrosurgical electrode 128 are rotatable together relative to handle 124 and at least one additional component in an internal cavity defined by shaft 126. Rotating electrosurgical electrode 128 relative to handle 124 can facilitate adjusting the angle of electrosurgical electrode 128 relative to one or more user input devices 130 of electrosurgical device 112. In this arrangement, a user can comfortably grasp handle 124 in a position where the user's fingers can comfortably operate user input device 130, while electrosurgical electrode 128 is set to a rotational position selected from among a plurality of rotational positions relative to handle 124 based, for example, on the location, size and / or shape of the surgical site at which the user is operating.

[0030] In one embodiment, electrosurgical electrode 128 can be rotatable greater than 360 degrees relative to handle 124. This can increase ease of use by allowing an operator to freely rotate electrosurgical electrode 128 without restriction. However, in other embodiments, electrosurgical electrode 128 can be rotatable less than 360 degrees (e.g., rotatable 180 degrees or rotatable 360 ​​degrees). This can still allow an operator to achieve a desired rotational arrangement, but it may be the case that the operator rotates in a first direction, reaches a stop position that limits further rotation, and then rotates back in a second direction to achieve the desired rotational arrangement.

[0031] While it can be advantageous to provide for rotation of the monopolar electrosurgical electrode 128 relative to the handle 124 and / or shaft 126, in some embodiments the monopolar electrosurgical electrode 128 may be rotationally fixed relative to the handle 124 and shaft 126. This may help simplify and reduce manufacturing costs, for example, by simplifying electrical connections that may otherwise be necessary to compensate for movement of the shaft 126 and handle 124 relative to one another (e.g., by omitting slip ring and / or sliding electrical contacts).

[0032] User input device 130 can select among operational modes of electrosurgical device 112 and / or electrosurgical generator 110. For example, in one embodiment, user input device 130 can be configured to select among a cut mode of operation and a coagulation mode of operation. In response to actuation of user input device 130 of electrosurgical device 112, electrosurgical device 112 can (i) receive electrosurgical energy having a power level and / or waveform corresponding to the operational mode selected via user input device 130, and (ii) deliver electrosurgical energy to electrosurgical electrode 128.

[0033] 1 , electrosurgical device 112 includes multiple electrical components that facilitate supplying electrosurgical energy that electrosurgical device 112 receives from electrosurgical generator 110 to electrosurgical electrode 128. For example, electrosurgical device 112 can include at least one electrical component selected from a group of electrical components including a printed circuit board 132 (e.g., a flexible printed circuit board), a housing conductor 134, and / or a shaft conductor 136 that can provide a circuit for conducting electrosurgical energy from power cord 122 to electrosurgical electrode 128. One or more of the electrical components can be positioned in an internal bore 125 defined by handle 124 and / or an internal cavity defined by shaft 126.

[0034] In an embodiment, user input device 130 may include one or more buttons on an exterior surface of handle 124. Each button of user input device 130 may be operable to actuate a respective one of a plurality of switches 138 on printed circuit board 132. Generally, switches 138 and / or printed circuit board 132 are operable to control the delivery of electrosurgical energy from electrosurgical generator 110 to electrosurgical electrode 128. For example, in one embodiment, each button may be actuated (e.g., pressed) to actuate a respective switch 138 associated with the button, which causes printed circuit board 132 to send a signal to electrosurgical generator 110 which in response provides electrosurgical energy having a power level and / or waveform corresponding to the operating mode associated with the button. In another embodiment, actuation of a button, thereby actuating a respective switch 138 associated with the button, may close switch 138, which completes a circuit to electrosurgical generator 110 which in response provides electrosurgical energy having a power level and / or waveform corresponding to the operating mode associated with the button. In some implementations of this embodiment, the printed circuit board 132 may be omitted.

[0035] In both exemplary embodiments, electrosurgical energy provided by electrosurgical generator 110 may be delivered by housing conductors 134 and shaft conductors 136 from (i) power cord 122, printed circuit board 132, and / or switch 138 to (ii) electrosurgical electrode 128. Thus, as shown in FIGURE 1, printed circuit board 132 may be coupled to power cord 122, housing conductors 134 may be coupled to printed circuit board 132 and shaft conductors 136, and shaft conductors 136 may be coupled to electrosurgical electrode 128. In this arrangement, housing conductors 134 may conduct electrosurgical energy (supplied to housing conductors 134 via printed circuit board 132) to shaft conductors 136, which may conduct electrosurgical energy to electrosurgical electrode 128.

[0036] Generally, housing conductors 134 and shaft conductors 136 may each include one or more conductive elements that provide a conductive bus for supplying electrosurgical energy to electrosurgical electrode 128. More specifically, housing conductors 134 may include one or more conductive elements of handle 124 that may supply electrosurgical energy to shaft conductors 136, and shaft conductors 136 may include one or more conductive elements of shaft 126 that may supply electrical energy from housing conductors 134 to electrosurgical electrode 128. In embodiments in which shaft 126 is movable and / or rotatable relative to handle 124, housing conductors 134 may engage shaft conductors 136 to maintain electrical coupling between housing conductors 134, shaft conductors 136, and electrosurgical electrode 128 while (i) shaft 126 and / or electrosurgical electrode 128 telescope relative to handle 124 and / or (ii) electrosurgical electrode 128 rotates relative to handle 124.

[0037] 1, user input device 130 may be separate from electrosurgical device 112 in alternative embodiments. For example, user input device 130 may additionally or alternatively include one or more foot pedals operable to control operation of electrosurgical device 112 as described above. The foot pedals may be communicatively coupled to electrosurgical generator 110 to provide a signal in response to actuation of the foot pedal.

[0038] 1, electrosurgical device 112 may additionally include one or more light sources 140 configured to emit light. Light source 140 may be optically coupled to optical lens assembly 142 configured to receive the light emitted by light source 140 and transmit the light distally toward the surgical site for illuminating the surgical site while performing electrosurgery using electrosurgical electrode 128. As described in further detail below with respect to FIGS. 4A-23, optical lens assembly 142 may direct the light emitted by light source 140 distally, thereby helping to enhance the quality of the light illuminating the surgical site.

[0039] In FIG. 1 , light source 140 may be coupled to shaft 126. As such, light source 140 may also telescopically move with shaft 126 relative to handle 124. However, in other embodiments, light source 140 may be in an internal bore of handle 124 and / or coupled to an exterior surface of handle 124. As examples, light source 140 may include one or more light emitting diodes (LEDs), organic light emitting diodes (OLEDs), optical fibers, non-fiber optical waveguides, and / or lenses. Additionally, for example, light source 140 may include a light emitting diode printed circuit board (LED PCB) having one or more light sources (e.g., LEDs). As described in more detail below, the LED PCB may include a PCB opening through which one or more other components of electrosurgical device 112 (e.g., electrosurgical electrode 128) may extend.

[0040] In embodiments including a light source 140, the user input device 130, the printed circuit board 132, the switch 138, the housing conductors 134, and / or the shaft conductors 136 may additionally provide power to the light source 140 from a direct current (DC) power source 144. In one embodiment, the DC power source 144 may include a battery located in the handle 124, a plug on the power cord 122, and / or a battery receptacle located along the power cord 122 between the handle 124 and the plug. Although the electrosurgical device 112 includes the DC power source 144 in FIG. 1, the DC power source 144 may be separate and distinct from the electrosurgical device 112 in other embodiments. For example, in another embodiment, the electrosurgical generator 110 may include the DC power source 144.

[0041] Additionally, in embodiments including light source 140, user input device 130 can be operable to cause light source 140 to emit light. In one example, user input device 130 can include a button that independently controls light source 140, separate from the buttons that control the electrosurgical mode of operation of electrosurgical device 112. In another example, user input device 130 and printed circuit board 132 can be configured such that operation of the button that controls the electrosurgical mode of operation simultaneously controls operation of light source 140 (e.g., light source 140 can be automatically activated to emit light when the button is operated to apply electrosurgical energy at electrosurgical electrode 128).

[0042] 1 , in response to manipulation of the user input device 130 to activate the light source 140, the DC power source 144 can provide power (e.g., a DC voltage) to the light source 140 via the printed circuit board 132, the housing conductors 134, and / or the shaft conductors 136. In this embodiment, one or more of the conductive elements of the housing conductors 134 can be configured to provide power from the DC power source 144 to the light source 140 and / or return power from the light source 140 to the DC power source 144. Thus, the housing conductors 134 can additionally or alternatively assist in providing electrical communication between the DC power source 144 and the light source 140 as the shaft 126 and the light source 140 telescope relative to the handle 124.

[0043] In the above-described embodiments, the user input device 130 on the handle 124 can be operated to control the operation of the light source 140, however, the light source 140 can additionally or alternatively be operated by one or more user input devices on the electrosurgical generator 110 (e.g., via the user interface 116) and / or at a plug in the power cord 122.

[0044] As mentioned above, the electrosurgical device 112 may additionally include features that provide for the evacuation of surgical smoke from the target tissue to a location external to the surgical site. Surgical smoke is a by-product of various surgical procedures. For example, during a surgical procedure, surgical smoke may be generated as a by-product of electrosurgical units (ESUs), lasers, electrocautery devices, ultrasound devices, and / or other powered surgical instruments (e.g., bone saws and / or drills). In some instances, surgical smoke may contain toxic gases and / or biological products resulting from the destruction of tissue. Additionally, surgical smoke may have an unpleasant odor. For these and other reasons, many guidelines indicate that surgeons' exposure to surgical smoke should be reduced or minimized.

[0045] To reduce (or minimize) exposure to surgical smoke, a smoke evacuation system may be used during a surgical procedure. Generally, a smoke evacuation system may include a suction pump 146 capable of generating sufficient suction and / or vacuum pressure to draw the surgical smoke away from the surgical site. In some embodiments, the smoke evacuation system may be coupled to an exhaust system (e.g., a wall-mounted exhaust system) that exhausts the surgical smoke from the operating room. In other embodiments, the smoke evacuation system may filter the air laden with surgical smoke and return the air to the operating room. In embodiments, the suction pump 146 and the electrosurgical generator 110 may be provided as separate devices or integrated in one device (e.g., in a common housing).

[0046] 1, shaft 126 may include a smoke evacuation channel 148 in the interior cavity of shaft 126. Smoke evacuation channel 148 may also include a smoke inlet that may extend circumferentially around a central axis of a distal portion of electrosurgical electrode 128. In this arrangement, the smoke inlet of the smoke evacuation channel may help admit surgical smoke into smoke evacuation channel 148 at all rotational alignment positions of electrosurgical electrode 128 relative to handle 124 and / or electrosurgical device 112 relative to the target tissue. However, in alternative embodiments, smoke evacuation channel 148 may include one or more smoke inlets that do not extend circumferentially around electrosurgical electrode 128.

[0047] In one embodiment, the smoke evacuation channel 148 can include an outer tube spaced apart from the optical lens assembly 142 by a gap. For example, the shaft 126 can include a number of standoffs extending between the optical lens assembly 142 and the outer tube of the smoke evacuation channel 148 to provide a gap between the outer tube and the optical lens assembly 142. In one embodiment, the optical lens assembly 142 can include the standoffs such that the optical lens assembly 142 and the standoffs are formed as a single monolithic structure. In another embodiment, the standoffs can be formed as a single monolithic structure with the outer tube of the smoke evacuation channel 148. In another embodiment, the standoffs can be separate from the outer tube of the smoke evacuation channel 148 and the optical lens assembly 142.

[0048] In one embodiment, the smoke evacuation channel 148 of the shaft 126 defines a first portion of the smoke flow path, and the internal bore of the handle 124 defines a second portion of the smoke flow path. Figure 2 shows a partial cross-sectional view of the electrosurgical device 112 according to an embodiment of this example. In this arrangement, surgical smoke may be received from the surgical site into the smoke evacuation channel 148 of the shaft 126 and flow proximally along the smoke evacuation channel 148 to the internal bore 125 of the handle 124. In the internal bore 125 of the handle 124, the smoke may further flow to a smoke tube 150 coupled to a proximal end of the handle 124 and configured to transport the smoke from the handle 124 to the suction pump 146.

[0049] As mentioned above, optical lens assembly 142 can help direct light emitted by light source 140 in a distal direction, thereby enhancing the quality of light illuminating the surgical site. Optical lens assembly 142 can be provided at the distal end of shaft 126. In some embodiments, optical lens assembly 142 can be disposed circumferentially around electrosurgical electrode 128 to emit light distally around all sides of electrosurgical electrode 128. This can help reduce shadows and provide greater uniformity of illumination at all rotational alignment positions of shaft 126 relative to handle 124 and / or electrosurgical device 112 relative to the target tissue.

[0050] In some embodiments, the smoke evacuation channel 148 and the optical lens assembly 142 can be coaxial. For example, the smoke evacuation channel 148 and the optical lens assembly 142 can each have a longitudinal axis that is coincident with the central axis of the shaft 126. It can be advantageous for efficient aspiration performance to position the smoke evacuation channel 148 such that the central axis of the smoke evacuation channel 148 is coincident with the central axis of the shaft 126. Similarly, it can be advantageous to position the electrosurgical electrode 128 so that it is aligned with the central axis of the shaft 126, for example, to provide a better line of sight in all rotational alignment positions and / or more intuitive handling.

[0051] In embodiments, optical lens assembly 142 can define a through bore, and smoke evacuation channel 148 and / or electrosurgical electrode 128 can extend through the through bore. In such an arrangement, electrosurgical electrode 128 can be centered on shaft 126, smoke evacuation channel 148 can extend around the circumference of electrosurgical electrode 128 and receive smoke, and optical lens assembly 142 can emit light and extend around electrosurgical electrode 128.

[0052] Figure 3 shows a simplified block diagram of electrosurgical device 112 shown in Figure 1 including additional features of optical lens assembly 142 according to one embodiment. In Figure 3, electrosurgical system 100 includes housing 123, electrosurgical electrode 128, a plurality of light sources 140 in housing 123, and optical lens assembly 142. Housing 123 has a proximal end and a distal end, and electrosurgical electrode 128 extends distally from the distal end of housing 123.

[0053] Also shown in FIG. 3 , the optical lens assembly 142 has a proximal end and a distal end. The optical lens assembly 142 includes a plurality of optical components 301 that are (i) coupled to one another at the distal end of the optical lens assembly 142 and (ii) spaced apart from one another at the proximal end of the optical lens assembly 142. In an embodiment, the optical components 301 do not have significant light transmission between one another (e.g., less than about 10% of the light from one optical component 301 passes through an adjacent optical component 301). This can help provide a relatively narrow beam of light. However, a portion of the light emitted by one of the optical components 301 can overlap with a portion of the light emitted by another optical component 301. This can provide a wider beam of light compared to an embodiment in which the optical components 301 do not have significant light transmission between one another.

[0054] In FIG. 3 , optical lens assembly 142 can include two or more optical components 301. More specifically, optical lens assembly 142 can include a quantity of optical components equal to N, where N is an integer value greater than 1. As shown in FIG. 3 , each optical component 301 is optically coupled to a respective light source 140 of multiple light sources 140. Thus, light source 140 can also include a quantity of light sources equal to N. In one embodiment, optical lens assembly 142 can include three or more optical components 301 and three or more light sources 140. This can help distribute optical components 301 about the longitudinal axis of shaft 126, which can enable optical lens assembly 142 to emit light distally and around electrosurgical electrode 128, thereby (i) reducing shadow formation and (ii) providing greater uniformity of illumination at all rotational alignment positions of electrosurgical electrode 128 relative to handle 124 and / or electrosurgical device 112 relative to target tissue.

[0055] As described in more detail below, at the proximal end of the optical lens assembly 142, each optical component 301 can define a cavity in which the respective light source 140 is disposed such that the light source 140 is distal to the proximal-most surface of the optical lens assembly 142. This can aid in better capturing and transmitting the wide-angle light beam emitted by the light source 140 as compared to other optical lenses in which the light source is disposed proximal to the proximal-most surface of the optical lens assembly. However, in some embodiments, the light source can be disposed proximal to the proximal-most surface of the optical lens assembly 142.

[0056] Each optical component 301 includes a proximal reflective surface 303 and a distal transmitting surface 305. The proximal reflective surface 303 extends distally from a respective light source 140 that is optically coupled to the optical component 301. The proximal reflective surface 303 is configured to reflect light emitted by the respective light source 140 toward a distal end of the optical component 301. In some embodiments, the proximal reflective surface 303 can have a spherical or parabolic shape configured to substantially collimate the light reflected by the proximal reflective surface 303.

[0057] In other embodiments, the proximal reflective surface 303 has an aspheric shape configured to substantially collimate light reflected by the proximal reflective surface 303. The aspheric shape of the proximal reflective surface 303 can provide greater efficiency and achieve a higher level of collimation of light than is possible with a parabolic or spherical reflective surface. In one embodiment, the aspheric shape of the proximal reflective surface 303 can be defined by Equation 1 below: z(r)= C*r^2 / (1+sqrt(1-C^2 *(K+1) * r^2) + a4 *r^4 + a6 *r^6+a8*r^8 (Equation 1) where C is the curvature, K is a conic constant, and a4, a6, and a8 are aspheric coefficients. Furthermore, in an embodiment, a proximal portion of the proximal reflective surface 303 can have a parabolic shape and a distal portion of the proximal reflective surface 303 can have an aspheric shape, which may also aid in collimating relatively wide angle light rays.

[0058] In an embodiment, the proximal reflective surface 303 can be a total internal reflection (TIR) ​​reflector. For example, the proximal reflective surface 303 and the housing 123 can be spaced apart from one another such that an air gap surrounds the proximal reflective surface 303. Arranging the proximal reflective surface 303 as a TIR reflector can help reduce additional manufacturing costs and / or biocompatibility requirements associated with metal reflectors typically incorporated into many conventional light devices (e.g., flashlights).

[0059] Distal transmitting surface 305 is at the distal end of optical lens assembly 142. Distal transmitting surface 305 is configured to output light distally from optical component 301. Each distal transmitting surface 305 of optical lens assembly 142 can include one or more features to control the output of light from optical lens assembly 142. In embodiments, at a plane distal to the distal end of electrosurgical electrode 128, the light emitted by optical lens assembly 142 can have a substantially uniform light intensity at each point in space. For example, the light emitted by optical lens assembly 142 can define a light pattern at a plane distal to the distal end of electrosurgical electrode 128, and the light intensity at the weakest portion of the light pattern can have an intensity that is at least 50 percent of the light intensity at the strongest portion of the light pattern.

[0060] In some embodiments, each distal transmitting surface 305 can be an aspheric lens configured to provide light in a substantially uniform manner. In one embodiment, each distal transmitting surface 305 can be segmented into a number of zones and a ray can be traced from each zone to the target plane. The aspheric surface can be configured such that the distribution of the ray provides a nearly uniform irradiance level within a defined area of ​​the target plane. For example, an aspheric lens can be designed by using Snell's law and ray tracing to determine the lens surface angle for each zone and then curve fitting the angles to an aspheric droop equation (e.g., Equation 1 above) to determine a continuous aspheric surface.

[0061] In another example, each distal transmitting surface 305 can be a Fresnel lens. For example, the Fresnel lens can have a flat surface at a distal end. The flat surface at the distal end can define a plurality of concentric rings, each of which can have a respective optical characteristic (e.g., Fresnel grooves defined by pitch, depth, angle, and / or curvature), and the optical characteristics of the plurality of rings can be different from one another, such that the flat surface at the distal end transmits light in a manner that approximates an aspheric lens (e.g., the different rings can differ in at least one of the pitch, depth, angle, and / or curvature of the Fresnel grooves). This can help improve focusing of light at the distal transmitting surface 305 while maintaining a relatively flat and compact shape.

[0062] In another embodiment, the distal transmitting surface 305 may include a plurality of lenslets at a distal end in one type of lens selected from a group of lens types consisting of spherical lenses, aspheric lenses, and Fresnel lenses. The lenslets may further help to increase the uniformity of the light intensity. For example, the lenslets may include a plurality of small spherical lenses arranged in a regular pattern. For example, the pattern may be hexagonal (e.g., each lenslet has six sides) or rectangular (e.g., each lenslet has four sides), with adjacent lenslets abutting each other. Each small spherical lenslet produces an image of the source. Thus, the lenslet array produces multiple images of the source. Because the lenslets include multiple lenses arranged close to each other, the images at least partially overlap each other, making it difficult for the human eye to distinguish one image from the other. As a result, the beam of light appears uniform and homogeneous.

[0063] Figures 4A-5B show two implementations of the optical lens assembly 142 of Figure 3 according to examples. In particular, Figures 4A and 5A show the assembly of the optical lens assembly 142 and the light source 140 according to first and second example embodiments, respectively, and Figures 4B and 5B show cross-sectional views through one optical component 301 of the optical lens assembly 142 and the light source 140 in Figures 4A and 5A, respectively.

[0064] As shown in FIGS. 4A-5B, optical lens assembly 142 has a proximal end 142A and a distal end 142B. Optical lens assembly 142 also includes optical components 301 that are (i) coupled together at distal end 142B of optical lens assembly 142 and (ii) spaced apart from one another at proximal end 142A of optical lens assembly 142. In these examples, optical components 301 are not in optical communication with one another. However, a portion of light emitted by one of optical components 301 may overlap with a portion of light emitted by another optical component to more uniformly distribute the light in a plane distal to the distal end of electrosurgical electrode 128. In one example, optical lens assembly 142 may be formed by a molding process.

[0065] 4A-5B, optical lens assembly 142 includes three optical components 301 and three light sources 140. As noted above, this can help distribute optical components 301 about longitudinal axis 413 of shaft 126, which can allow optical lens assembly 142 to emit light distally and around electrosurgical electrode 128 to reduce shadow formation. Additionally, for example, three optical components 301 and three light sources 140 can provide a desired quality of light in a more compact arrangement and with lower power requirements than other embodiments that include different amounts of optical components 301 and light sources 140. However, in other embodiments, optical lens assembly 142 can include different amounts of optical components 301 and light sources 140.

[0066] In the illustrated embodiment, the light source 140 includes a plurality of LEDs coupled to an LED PCB 407. The LED PCB 407 may be in the form of a ring having a PCB opening 409 that extends completely through the LED PCB 407. The optical lens assembly 142 may also include a lens opening 411 that passes through the optical lens assembly 142 and defines a through bore. The PCB opening 409 of the LED PCB 407 may be aligned with the lens opening 411 of the optical lens assembly 142 such that one or more other components of the electrosurgical device 112 (e.g., the electrosurgical electrode 128 and / or the smoke evacuation channel 148) may extend through the LED PCB 407 and the optical lens assembly 142 while the LEDs are disposed about the components.

[0067] For example, light sources 140 can be arranged circumferentially around longitudinal axis 413 of electrosurgical electrode 128, with longitudinal axis 413 extending between a proximal end of electrosurgical electrode 128 and a distal end of electrosurgical electrode 128. In Figures 4A-5B, three light sources 140 are equally spaced around longitudinal axis 413 of electrosurgical electrode 128, and a lens aperture 411 defined by optical lens assembly 142 has a central axis that is collinear with longitudinal axis 413 of electrosurgical electrode 128. This can help to increase the uniformity of light around electrosurgical electrode 128.

[0068] Additionally, for example, a suction tube defining smoke evacuation channel 148 can extend through PCB opening 409 in LED PCB 407 and lens opening 411 in optical lens assembly 142. In this arrangement, light source 140 can be positioned around the suction tube and distal end 142B of optical lens assembly 142 can extend around the suction tube to evacuate smoke and emit light around electrosurgical electrode 128.

[0069] As shown in Figures 4A and 5A, the optical lens assembly 142 includes an inner surface and an outer surface. The inner surface defines the lens aperture 411 and the through bore of the optical lens assembly 142. In one embodiment, between the proximal reflective surface 303 and the distal transmissive surface 305, the cross section of the optical lens assembly 142 is circular on the inner surface and non-circular on the outer surface. This allows the optical lens assembly 142 to rotate relative to components extending through the through bore of the optical lens assembly 142 while preventing rotation of the optical lens assembly 142 relative to components adjacent the outer surface. By way of example, the non-circular shape can be elliptical, polygonal, and / or non-polygonal.

[0070] In another embodiment, the inner surface can have a non-circular cross-sectional shape while the outer surface is circular to permit rotation of peripherally disposed components and prevent rotation of internally disposed components relative to the optical lens assembly 142. In another embodiment, both the inner and outer surfaces can have circular cross-sectional shapes to permit rotation of adjacent components or both the inner and outer surfaces can be non-circular to prevent rotation of adjacent components.

[0071] 4B and 5B, at the proximal end 142A of the optical lens assembly 142, each optical component 301 can define a cavity 415 in which a respective light source 140 is disposed such that the light source 140 is located distal to a proximal-most surface of the optical lens assembly 142. Additionally, each optical component 301 is separated from a respective light source 140 optically coupled to the optical component 301 by an air gap. This can help to better capture and transmit the wide-angle light beam emitted by the light source 140 as compared to other optical lenses in which the light source is located proximal to a proximal-most surface of the optical lens assembly 142.

[0072] 4A-5B, each optical component 301 includes a proximal reflective surface 303 and a distal transmissive surface 305. The proximal reflective surface 303 extends distally from a respective light source 140 that is optically coupled to the optical component 301. The proximal reflective surface 303 is configured to reflect light emitted by the respective light source 140 toward a distal end of the optical component 301.

[0073] 4A-5B, the proximal reflective surface 303 has an aspheric shape configured to substantially collimate light reflected by the proximal reflective surface 303. The aspheric shape of the proximal reflective surface 303 can provide greater efficiency and achieve a higher level of collimation of light than is possible with a parabolic or spherical reflective surface. Furthermore, in an embodiment, a proximal portion of the proximal reflective surface 303 can have a parabolic shape and a distal portion of the proximal reflective surface 303 can have an aspheric shape. This may also aid in collimating relatively wide angle light rays.

[0074] As described above, the proximal reflective surface 303 can be a TIR reflector. For example, the proximal reflective surface 303 and the housing 123 can be spaced apart from one another such that an air gap surrounds the proximal reflective surface 303. Arranging the proximal reflective surface 303 as a TIR reflector can help alleviate additional manufacturing costs and / or biocompatibility requirements associated with metal reflectors.

[0075] Distal transmitting surface 305 is located at distal end 142B of optical lens assembly 142. Distal transmitting surface 305 is configured to output light distally from optical component 301. As described above, each distal transmitting surface 305 of optical lens assembly 142 may include one or more features to control the output of light from optical lens assembly 142. For example, each distal transmitting surface 305 is a Fresnel lens in FIGS. 4A-4B and each distal transmitting surface 305 is an aspheric surface in FIGS. 5A-5B.

[0076] FIG. 6 shows a simplified block diagram of a light source 140, according to one embodiment. In FIGS. 4B, 5B, and 6, each light source 140 is an LED 617 that includes a die 619 and a protective layer 621. The protective layer 621 can be, for example, a layer of optically transparent material, such as a layer of silicone material. The protective layer 621 can be a non-rigid structure (e.g., a coating) as opposed to a rigid silicone lens that protects the underlying diode structure in a conventional LED. This is possible, at least in part, because the light source 140 is disposed in the cavity 415 of the optical component 301 such that the optical component 301 can protect the die 619.

[0077] By using a non-rigid protective layer 621 instead of a rigid silicone lens, the overall size of each LED 617 can be reduced. This can help reduce the size of the optical lens assembly 142 while maintaining the ratio of the optical diameter to the LED diameter. For example, in a conventional LED, the rigid silicone lens is typically about 200% larger than the diameter of the die 619. In contrast, an LED with the non-rigid protective layer 621 described above can have a diameter that is about 10% to about 50% larger than the diameter of the die 619. As an example, each LED 617 can have a diameter of about 1 millimeter (mm) to about 2 mm. Thus, the light source 140 described above can help solve the problem of space constraints and improve light capture from a light source having a wide Lambertian optical pattern.

[0078] 7A-13 illustrate an embodiment of the electrosurgical device 112 shown in FIG. 1 including the optical lens assembly 142 shown in FIGS. 4A-4B according to one embodiment. As shown in FIGS. 7A-7B, the housing 123 of the electrosurgical device 112 includes a handle 124 having a proximal end and a distal end, and a shaft 126 extending from the distal end of the handle 124. An electrosurgical electrode 128 extends from the distal end of the shaft 126, and a number of light sources 140 are disposed on the shaft 126. The handle 124 defines an internal bore 125, and the shaft 126 extends distally from the internal bore 125 of the handle 124. Also, in FIGS. 7A-7B, a distal portion 128A of the electrosurgical electrode 128 extends distally from the shaft 126. In some embodiments, distal portion 128A of electrosurgical electrode 128 defines a working end configured to apply electrosurgical energy to tissue.

[0079] 7A-7B, shaft 126 is telescopingly movable in an internal bore 125 of handle 124 to adjust the distance of a distal-most tip of electrosurgical electrode 128 relative to handle 124. For example, FIG. 7A shows shaft 126 in a first position relative to handle 124 along the longitudinal axis of electrosurgical device 112, and FIG. 7B shows shaft 126 in a second position relative to handle 124 along the longitudinal axis of electrosurgical device 112. In FIGS. 7A-7B, the first position is more proximal than the second position, such that shaft 126 is in a retracted position within handle 124 in the first position and shaft 126 is in an extended position from handle 124 in the second position. As discussed above, telescoping shaft 126 relative to handle 124 can facilitate adjusting the length of the electrosurgical device to treat target tissues of different sizes and / or shapes. However, as discussed above, in other embodiments, the shaft 126 can be fixedly coupled to the handle 124 such that the shaft 126 is not moveable relative to the handle 124 .

[0080] In some embodiments, the electrosurgical device 112 can include a collar 762 at the proximal end of the handle 124. The collar 762 can be rotatable relative to the handle 124 to increase and / or reduce friction between an outer surface of the shaft 126 and an inner surface of the collar 762. The collar 762 thereby allows and / or prevents axial telescopic movement of the shaft 126 relative to the handle 124.

[0081] 7A-7B, shaft 126 is rotationally fixed relative to handle 124, and electrosurgical electrode 128 is rotatable relative to handle 124 and shaft 126. This can simplify the design and reduce the manufacturing costs of electrosurgical device 112. For example, this arrangement of handle 124, shaft 126 and electrosurgical electrode 128 can simplify the electrical connections between housing conductors 134, shaft conductors 1236 and electrosurgical electrode 128. Additionally, this arrangement can help reduce damage to the electrical connections during telescoping movement of shaft 126 relative to handle 124 and / or rotation of electrosurgical electrode 128 relative to shaft 126 and handle 124.

[0082] 8-13 illustrate additional aspects of electrosurgical device 112 that can facilitate the telescoping and rotational movements described above. FIG. 8 illustrates a partially exploded view of handle 124. As shown in FIG. 8, handle 124 can include an upper portion 864A that can be coupled to a lower portion 864B to define an internal bore 125 between upper portion 864A and lower portion 864B. Generally, internal bore 125 can be a space within handle 124 that can accommodate one or more components of electrosurgical device 112.

[0083] In the internal bore 125 of the handle 124, the electrosurgical device 112 includes a shaft guide 866 extending along a direction parallel to the longitudinal axis of the handle 124 (e.g., extending between the proximal end 124A of the handle 124 and the distal end 124B of the handle 124). The shaft guide 866 is configured to extend in an internal cavity 868 of the shaft 126. The internal cavity 868 of the shaft 126 may be a bore extending between the proximal end 126A of the shaft 126 and the distal end 126B of the shaft 126 (shown in FIGS. 7A-7B). Thus, the internal cavity 868 may be defined by an inner surface of the shaft 126.

[0084] 8, the shaft guide 866 can have a non-circular cross-sectional shape to help prevent rotation between the shaft 126 and the handle 124. For example, an outer surface of the shaft guide 866 that extends in the internal cavity 868 of the shaft 126 can have a non-circular shape that engages with a non-circular shape of an inner surface of the shaft 126 in the internal cavity 868 of the shaft 126. In this arrangement, the shaft 126 can slide proximally and distally (e.g., along the longitudinal axis of the handle 124) over the shaft guide 866, but the shaft 126 is prevented from rotating relative to the shaft guide 866 due to the engagement between (i) the inner surface of the internal cavity 868 of the shaft 126 and (ii) the outer surface of the shaft guide 866.

[0085] Also, as shown in FIG. 8, the shaft guide 866 is rotationally fixed relative to the handle 124. For example, a portion of the shaft guide 866 can have a non-circular shape that can engage a structure in the handle 124 having a corresponding shape. In FIG. 8, for example, a proximal portion of the shaft guide 866 has a hexagonal feature that engages a hexagonal socket formed in an inner wall of the handle 124 (e.g., an inner wall of the upper portion 864A and / or lower portion 864B of the handle 124) to prevent rotation between the shaft guide 866 and the handle 124. In this arrangement, the shaft 126 is rotationally fixed relative to the handle 124 as a result of a first non-rotating engagement between the shaft 126 and the shaft guide 866 and a second non-rotating engagement between the shaft guide 866 and the handle 124.

[0086] As mentioned above, electrosurgical electrode 128 is coupled to shaft 126 such that electrosurgical electrode 128 is rotatable relative to handle 124 and shaft 126. An exemplary arrangement for coupling electrosurgical electrode 128 to shaft 126 in a manner that permits such rotation of electrosurgical electrode 128 is shown in Figures 9-10. Figure 9 shows a cross-sectional view of handle 124, shaft 126 and a distal portion of electrosurgical electrode 128 for the example embodiment shown in Figures 7A-7B. Figure 9 also shows electrical contacts 970 of a portion of housing conductor 134 and shaft conductor 136 according to an example. Figure 10 shows a perspective view of electrical contact 970 shown in Figure 9.

[0087] 9, shaft 126 may include an electrical contact 970 coupled to a proximal portion 128B of electrosurgical electrode 128. In particular, electrical contact 970 is coupled to proximal portion 128B of electrosurgical electrode 128 such that electrosurgical electrode 128 is rotatable relative to electrical contact 970. In this embodiment, electrosurgical electrode 128 and electrical contact 970 are electrically coupled in all rotational positions of electrosurgical electrode 128 relative to electrical contact 970.

[0088] In embodiments, electrical contacts 970 may frictionally engage proximal portion 128B of electrosurgical electrode 128 such that (i) electrical contacts 970 prevent rotation of electrosurgical electrode 128 relative to electrical contacts 970 when a force less than a threshold force is applied to electrosurgical electrode 128, and (ii) electrical contacts 970 permit rotation of electrosurgical electrode 128 relative to electrical contacts 970 when a force greater than the threshold force is applied to electrosurgical electrode 128. The threshold force may be an amount of force large enough to prevent electrosurgical electrode 128 from freely rotating under gravity alone and / or to prevent electrosurgical electrode 128 from rotating when electrosurgical electrode 128 is used to cut and / or coagulate tissue. The threshold force may additionally or alternatively be an amount of force low enough that a user may manually rotate electrosurgical electrode 128 relative to handle 124 without the use of a separate tool or instrument.

[0089] To help provide frictional engagement between proximal portion 128B of electrosurgical electrode 128 and electrical contacts 970, electrical contacts 970 can extend around at least halfway around proximal portion 128B of electrosurgical electrode 128. For example, in FIG. 10 , electrical contacts 970 include a pair of arms 971 that extend around more than halfway around proximal portion 128B of electrosurgical electrode 128 and are biased inwardly to apply a force to proximal portion 128B of electrosurgical electrode 128. The force applied by electrical contacts 970 can thereby help control the rotation of electrosurgical electrode 128 relative to shaft 126 and handle 124. Additionally, in this arrangement, arms 971 of electrical contacts 970 can permit electrosurgical electrode 128 to rotate more than 360 degrees about an axis of rotation (e.g., a central axis of electrosurgical electrode 128).

[0090] Electrical contact 970 may also assist in axially retaining electrosurgical electrode 128 in internal cavity 868 of shaft 126. For example, proximal portion 128B of electrosurgical electrode 128 may include a first shoulder 972A that may engage electrical contact 970 to block or prevent axial movement of electrosurgical electrode 128 relative to shaft 126 in a distal direction. Additionally, for example, proximal portion 128B of electrosurgical electrode 128 may include a second shoulder 972B that may engage a stop 973 of shaft 126 to block axial movement of electrosurgical electrode 128 relative to shaft 126 in a proximal direction.

[0091] In some embodiments, the engagement between the first shoulder 972A and the electrical contact 970 can inhibit or prevent removal of the electrosurgical electrode 128 from the shaft 126 such that the electrosurgical electrode 128 is fixedly coupled to the shaft 126. In alternative embodiments, the engagement between the first shoulder 972A and the electrical contact 970 can allow the electrosurgical electrode 128 to be removed and replaced with another electrosurgical electrode 128.

[0092] Additionally, as shown in FIGS. 9-10 , the electrical contact 970 can include a first end 970A coupled to the proximal portion 128B of the electrosurgical electrode 128 and a second end 970B extending into the handle 124. As shown in FIG. 9 , the second end 970B engages a housing conductor 134 that extends along the handle 124 in a direction parallel to the longitudinal axis of the handle 124. In this embodiment, the second end 970B of the electrical contact 970 is configured to remain engaged with the housing conductor 134 while the shaft 126 moves in a telescoping manner relative to the handle 124. For example, the electrical contact 970 is fixedly coupled to the shaft 126 such that the electrical contact 970 moves with the shaft 126 relative to the handle 124. In this arrangement, the second end 970B of the electrical contact 970 may be continuously engaged and electrically coupled to the housing conductor 134, while the second end 970B slides along the housing conductor 134 in response to axial movement of the shaft 126 relative to the handle 124. This allows the electrical contact 970 to facilitate delivery of electrosurgical energy to the electrosurgical electrode 128 at any rotational and / or axial position of the electrosurgical electrode 128 relative to the handle 124.

[0093] As shown in FIG. 9, the shaft 126 can also include a smoke evacuation channel 148 that extends from the proximal end 126A of the shaft 126 to the distal end 126B of the shaft 126. For example, in FIGS. 7A, 7B and 9, the electrosurgical electrode 128 extends through the interior cavity 868 of the shaft 126 such that the smoke evacuation channel 148 can include a gap defined between the electrosurgical electrode 128 and the inner surface of the shaft 126. In the illustrated embodiment, the shaft 126 has a central axis that extends between the proximal end 126A and the distal end 126B, and the electrosurgical electrode 128 has a central axis that is collinear with the central axis of the shaft 126. In this arrangement, the smoke evacuation channel 148 can have a substantially constant size around the circumference of the electrosurgical electrode 128. This can help provide a relatively constant suction at each point around the circumference of the electrosurgical electrode 128. However, in other embodiments, the central axes of electrosurgical electrode 128 and shaft 126 can be offset and parallel with respect to one another.

[0094] 8, an internal cavity 868 at the proximal end 126A of the shaft 126 can provide a proximal end of the smoke evacuation channel 148 (shown in FIG. 9). The proximal end of the smoke evacuation channel 148 can be in fluid communication with the smoke evacuation chamber 152 of the handle 124. For example, in FIG. 8, the smoke evacuation chamber 152 can include a bore 874 in the shaft guide 866 and a portion of the internal bore 125 of the handle 124 proximal to the shaft guide 866.

[0095] 9, electrosurgical device 122 may also include a suction sleeve 975 that may be fluidly coupled to smoke evacuation channel 148 in shaft 126. As shown in FIG. 9, a distal portion of suction sleeve 975 may extend distally from distal end 126B of shaft 126, and electrosurgical electrode 128 may extend through suction sleeve 975. In particular, suction sleeve 975 may be spaced from electrosurgical electrode 128 to define a smoke inlet that may extend circumferentially around a central axis of distal portion 128A of electrosurgical electrode 128.

[0096] In one embodiment, suction sleeve 975 may be rotationally fixed relative to electrosurgical electrode 128 such that rotation of suction sleeve 975 relative to shaft 126 results in a corresponding rotation of electrosurgical electrode 128 relative to shaft 126 and handle 124. In this arrangement, a user may use suction sleeve 975 to rotate electrosurgical electrode 128 relative to handle 124. This may advantageously allow a user to avoid directly touching electrosurgical electrode 128, which may be relatively hot after and during use. Additionally, suction sleeve 975 may help maintain the structural integrity and operational performance of electrosurgical electrode 128, since directly touching electrosurgical electrode 128 may adversely affect a coating on electrosurgical electrode 128.

[0097] 9 , suction sleeve 975 includes one or more teeth 976 and electrosurgical electrode 128 includes one or more slots 977. Each of the one or more teeth 976 of suction sleeve 975 is received in a respective one of the one or more slots 977 such that the one or more teeth 976 engage the one or more slots 977 to rotate electrosurgical electrode 128 in response to rotation of suction sleeve 975. However, in alternative embodiments, suction sleeve 975 can include one or more slots 977 and electrosurgical electrode 128 can include one or more teeth 976.

[0098] In some embodiments, the suction sleeve 975 can be telescopingly movable in the internal cavity 868 of the shaft 126 to adjust the distance between the suction sleeve 975 and the distal-most tip of the electrosurgical electrode 128. For example, each of the one or more teeth 976 can be configured to slide longitudinally in a respective one of the one or more slots 977 in response to the suction sleeve 975 moving telescopingly relative to the shaft 126 and / or the electrosurgical electrode 128. In this telescoping arrangement, the suction sleeve 975 can be moved relative to the shaft 126 and the electrosurgical electrode 128 to adjust the extent to which the distal portion 128A of the electrosurgical electrode 128 is exposed. In particular, the suction sleeve 975 can be moved (i) toward the distal end 126B of the shaft 126 to expose a greater area of ​​the electrosurgical electrode 128 and increase visibility at the surgical site, and (ii) away from the distal end 126B of the shaft 126 to expose a lesser area of ​​the electrosurgical electrode 128 and capture a relatively greater amount of smoke at the surgical site.

[0099] Although it may be advantageous for the suction sleeve 975 to be telescopically movable relative to the shaft 126 and / or electrosurgical electrode 128, in other embodiments the suction sleeve 975 may be axially fixed relative to the shaft 126 and / or electrosurgical electrode 128. This may simplify manufacture and reduce manufacturing costs.

[0100] In one embodiment, the suction sleeve 975 can be substantially transparent such that the electrosurgical electrodes 128 can be viewed through the suction sleeve 975. This can help to enhance the visibility of the electrosurgical electrodes 128. However, in other embodiments, the suction sleeve 975 can be formed from an opaque material.

[0101] Figure 11 shows a distal portion of shaft 126 with the upper portion removed to show the optical components disposed in internal cavity 868 of shaft 126. Figure 12 shows optical lens assembly 142 shown in Figures 4A-4B with electrosurgical electrode 128 and suction sleeve 975, which defines a portion of smoke evacuation channel 148, extending through lens opening 411 of optical lens assembly 142 and PCB opening 409 of LED PCB 407.

[0102] 9 and 11-12, electrosurgical device 112 can include a light source 140 and an optical lens assembly 142 in an interior cavity 868 of shaft 126. As described above, light source 140 is configured to emit light into optical lens assembly 142, which is configured to transmit light distally from light source 140 and emit light from distal end 126B of shaft 126.

[0103] As shown in FIG. 12, electrosurgical electrode 128 and suction sleeve 975 can extend through a through bore defined by PCB opening 409 in LED PCB 407 and lens opening 411 in optical lens assembly 142. Additionally, as shown in FIG. 12, light source 140 can be positioned around electrosurgical electrode 128. In this arrangement, electrosurgical device 112 can provide illumination and suction around electrosurgical electrode 128. Furthermore, integrating optical lens assembly 142 of FIGS. 3-4B in this arrangement can improve the quality of illumination, reduce the size of the distal end of the electrosurgical device, and improve the line of sight to the surgical site.

[0104] 11, the electrosurgical device 112 may also include a heat sink 1180 coupled proximally to the light source 140. This may help reduce the temperature of the light source 140, and therefore the electrosurgical device 112.

[0105] In one embodiment, light source 140, optical lens assembly 142 and / or heat sink 1180 can be fixedly coupled to shaft 126. In this arrangement, electrosurgical electrode 128 and suction sleeve 975 can be rotatable relative to light source 140, optical lens assembly 142 and / or heat sink 1180. For example, openings in light source 140, optical lens assembly 142 and / or heat sink 1180 can have a size and / or shape (e.g., a circular shape) that allows electrosurgical electrode 128 and suction sleeve 975 to rotate in the openings. Additionally, in this arrangement, light source 140, optical lens assembly 142 and heat sink 1180 can be telescopically movable relative to handle 124 along with shaft 126.

[0106] As described above, the housing conductors 134 and the shaft conductors 136 can be provided to electrically couple the light source 140 to the DC power source 144. FIG. 13 illustrates the electrosurgical device 112 of FIGS. 7A-12 with components removed to show the housing conductors 134 and the shaft conductors 136 for providing DC power to the light source 140, according to one embodiment. As shown in FIG. 13, the shaft 126 can include a positive-photoconductor 1336A and a negative-photoconductor 1336B that slidably engage corresponding conductors 1334A, 1334B in the handle 124 during axial telescoping movement of the shaft 126 relative to the handle 124.

[0107] As shown in FIGS. 7A-8 and 13, user input device 130 includes a first button 730A and a second button 730B on an exterior surface of handle 124. In one embodiment, first button 730A can be actuated to operate electrosurgical device 122 in a cutting mode of operation, and second button 730B can be actuated to operate electrosurgical device 122 in a coagulation mode of operation. In this example, a third button (not shown) can be provided on a plug of power cord 122 and / or on electrosurgical generator 110, and the third button can be actuated to operate light source 140 (i.e., to cause light source 140 to emit light or to stop emitting light). As mentioned above, user input device 130 can be configured differently in other examples. For example, electrosurgical device 112 can be operable in a lower amount of operation mode, a higher amount of operation mode, and / or different types of operation modes in other examples (e.g., the exemplary operation modes described above, etc.). Additionally, for example, the at least one user input device 130 can additionally or alternatively include a user interface 116 of the electrosurgical generator 110 and / or another external device (e.g., a foot switch) for operating the electrosurgical device 112 in one or more operating modes. Also, for example, the user input device 130 on the handle 124 can include a third button for operating the light source 140.

[0108] Figures 14-20 show an implementation of electrosurgical device 112 of Figure 1 and optical lens assembly 142 of Figures 5A-5B according to another embodiment. Figure 14 shows a perspective view of electrosurgical device 112 according to an embodiment. Figure 15 shows a cross-sectional view of electrosurgical device 112 taken along longitudinal axis 1482 of the electrosurgical device according to an embodiment.

[0109] 14-15, electrosurgical device 112 includes a handle 124 defining an internal bore 125, a shaft 126 extending distally from internal bore 125 of handle 124, and a smoke evacuation channel 148 in an internal cavity 1468 of shaft 126. Shaft 126 has a longitudinal axis 1482 extending between a proximal end 126A of shaft 126 and a distal end 126B of shaft 126. Additionally, an electrosurgical electrode 128 extends distally from distal end 126B of shaft 126.

[0110] In one embodiment, shaft 126 may be telescopingly movable in an internal bore 125 of handle 124 to adjust the distance of a distal-most tip of electrosurgical electrode 128 relative to handle 124. As noted above, telescoping shaft 126 relative to handle 124 may facilitate adjusting the length of the electrosurgical device to treat target tissue of different sizes and / or shapes. However, as noted above, in other embodiments, shaft 126 may be fixedly coupled to handle 124 such that shaft 126 is not movable relative to handle 124.

[0111] In some embodiments, the electrosurgical device 112 can include a collar 1462 at the proximal end of the handle 124. The collar 1462 can be rotatable relative to the handle 124 to increase and / or decrease friction between an outer surface of the shaft 126 and an inner surface of the collar 1462. In this way, the collar 1462 can allow and / or prevent axial telescopic movement of the shaft 126 relative to the handle 124.

[0112] 14-15 , shaft 126 is rotatable relative to handle 124, and smoke evacuation channel 148 is rotationally fixed relative to handle 124. Additionally, as described in more detail below, electrosurgical device 112 may further include light source 140 of FIGS. 5A-5B and optical lens assembly 142, both of which may be rotationally fixed relative to handle 124. Providing for rotation of electrosurgical electrode 128 along with shaft 126 while rotationally fixing smoke evacuation 148, light source 140 and / or optical lens assembly 142 may help simplify the design and / or reduce manufacturing costs of electrosurgical device 112.

[0113] The rotational arrangement of these components of electrosurgical device 112 can be achieved, at least in part, as a result of (i) shaft 126 conducting electrosurgical energy to electrosurgical electrode 128, and (ii) electrosurgical electrode 128 extending distally from distal end 126B of shaft 126, such that rotation of shaft 126 relative to handle 124 results in corresponding rotation of electrosurgical electrode 128 relative to handle 124. For example, at least a portion of shaft 126 can be formed from an electrically conductive material, such that shaft 126 is a shaft conductor 136 (e.g., a conductive tube that at least partially defines an interior cavity 1468) for supplying electrosurgical energy to electrosurgical electrode 128.

[0114] In one embodiment, electrosurgical electrode 128 and shaft 126 are formed as a single piece, monolithic structure. This may be advantageous in embodiments where electrosurgical electrode 128 is permanently fixed to shaft 126 such that electrosurgical electrode 128 cannot be replaced with another electrosurgical electrode 128. In another embodiment, electrosurgical electrode 128 and shaft 126 may be separate components that are joined together (e.g., by welding, soldering and / or a friction fit connection). In some embodiments where electrosurgical electrode 128 and shaft 126 are separate components, electrosurgical electrode 128 may be removable from shaft 126 and replaced with another electrosurgical electrode 128. In other embodiments, electrosurgical electrode 128 may be permanently fixed to shaft 126 such that electrosurgical electrode 128 cannot be replaced with another electrosurgical electrode 128.

[0115] 14-15, shaft 126 includes conductive portion 126C and insulator portion 126D. As described above, electrosurgical electrode 128 can extend from conductive portion 126C of shaft 126. Insulator portion 126D of shaft 126 can be a sleeve structure that covers the interface between electrosurgical electrode 128 and conductive portion 126C of shaft 126. In this arrangement, insulator portion 126D can help mitigate arcing and / or help deliver electrosurgical energy to electrosurgical electrode 128. Additionally, shaft 126 can include a layer of insulator material 126E (e.g., heat shrink material) that covers the remainder of conductive portion 126C of shaft 126 (e.g., the portion of shaft 126 not covered by insulator portion 126D) to help mitigate arcing and / or deliver electrosurgical energy to electrosurgical electrode 128.

[0116] 16, there is shown an enlarged view of a cross-section of distal end 126B of shaft 126 and electrosurgical electrode 128 taken along longitudinal axis 1482, according to one embodiment. As shown in FIG. 16, distal portion 128A of electrosurgical electrode 128 can define a working end configured to apply electrosurgical energy to tissue. Proximal portion 128B of electrosurgical electrode 128 can include a first leg 1684A extending from distal end 126B of shaft 126 and a second leg 1684B extending from a distal end of conductive portion 126C of shaft 126.

[0117] 16 , first leg 1684A and second leg 1684B are diametrically opposed to one another along the circumference of distal end 126B of shaft 126. Additionally, proximally-facing surface 1685 of proximal portion 128B of electrosurgical electrode 128 can taper distally toward the central axis of shaft 126 to define a gap 1686 between proximally-facing surface 1685 and a flat surface 1687 at the distal-most end of shaft 126. Gap 1686 can help enhance airflow and suction at distal end 126B of shaft 126.

[0118] 16, the sleeve structure of insulator portion 126D can extend around optical lens assembly 142. The sleeve structure can be an optically opaque material. To increase the intensity of light emitted from optical lens assembly 142, at least a portion of a distal transmissive surface of each of optical lens assemblies 142 can extend to a position distal to a distal-most end of the sleeve structure of insulator portion 126D.

[0119] 15, the shaft 126 can include an electrical contact 1570 that engages a housing conductor 134 that extends along the handle 124 in a direction parallel to the longitudinal axis 1482 (as shown in FIG. 14) of the handle 124. The electrical contact 1570 can be configured to remain engaged with the housing conductor 134 while the shaft 126 moves telescopically relative to the handle 124. For example, the electrical contact 1570 is fixedly coupled to the shaft 126 such that the electrical contact 1570 moves with the shaft 126 relative to the handle 124. In this arrangement, the electrical contact 1570 can be continuously engaged and electrically coupled to the housing conductor 134 while the electrical contact 1570 slides along the housing conductor 134 in response to axial movement of the shaft 126 relative to the handle 124.

[0120] Additionally, the electrical contacts 1570 can extend around the circumference of the shaft 126 such that the electrical contacts 1570 can remain engaged with the housing conductors 134 at all rotational positions of the shaft 126 and the electrosurgical electrode 128 relative to the handle 124. This allows the electrical contacts 1570 to facilitate the delivery of electrosurgical energy to the electrosurgical electrode 128 at all rotational and / or axial positions of the electrosurgical electrode 128 relative to the handle 124.

[0121] In one embodiment, shaft 126 and electrosurgical electrodes 128 can be rotatable greater than 360 degrees relative to handle 124. In this embodiment, electrical contacts 1570 can extend entirely around shaft 126. In another embodiment, shaft 126 and electrosurgical electrodes 128 can be rotatable less than 360 degrees relative to handle 124. In such an embodiment, electrical contacts 1570 can extend at least partially around shaft 126 sufficient to maintain electrical coupling between shaft 126 and housing conductors 134 over the full range of rotational positions that shaft 126 and electrosurgical electrodes 128 can be in relative to handle 124.

[0122] As described above, electrosurgical electrode 128 may include a proximal portion 128B extending from the distal end of shaft 126 and a distal portion 128A with a working end configured to apply electrosurgical energy to tissue. In FIGS. 14-16, the central axis of distal portion 128A of electrosurgical electrode 128 and the central axis of smoke evacuation channel 148 are collinear. In this arrangement, smoke evacuation channel 148 may have a substantially constant size along the circumference of electrosurgical electrode 128. This may help provide a relatively constant suction at each point around the circumference of electrosurgical electrode 128. However, in other embodiments, the central axes of electrosurgical electrode 128 and shaft 126 may be offset and parallel with respect to one another.

[0123] Additionally, as shown in Figures 14-16, the smoke evacuation channel 148 can define a space devoid of any other structure between the proximal end 148A of the smoke evacuation channel 148 and the distal end 148B of the smoke evacuation channel 148. This can provide for more efficient use of the relatively limited size of the interior cavity 1468 to enhance suction via the smoke evacuation channel 148, as compared to other embodiments in which the electrosurgical electrode 128 and / or other components are disposed in the smoke evacuation channel 148.

[0124] Additionally, as described above, smoke evacuation channel 148 may be rotationally fixed relative to handle 124 such that shaft 126 and electrosurgical electrode 128 are rotatable relative to smoke evacuation channel 148. Figures 17-18 show smoke evacuation channel 148 and shaft 126 according to one embodiment. As shown in Figures 15 and 17-18, at least a portion of smoke evacuation channel 148 may have a non-circular shape to prevent rotation of smoke evacuation channel 148 relative to handle 124 while shaft 126 and electrosurgical electrode 128 rotate relative to handle 124.

[0125] For example, the proximal end 148A of the smoke evacuation channel 148 can include a non-rotating fitting configured to engage a correspondingly shaped structure in the handle 124, where the non-rotating fitting can have a non-circular cross-sectional shape. In Figures 15 and 17, for example, the proximal end 148A of the smoke evacuation channel 148 has a hexagonal feature that engages with a hexagonal socket formed in an inner wall of the handle 124 to prevent rotation between the smoke evacuation channel 148 and the handle 124. Additionally, as shown in Figure 18, a gap can be defined between the shaft 126 and the smoke evacuation channel 148 to accommodate rotation of the shaft 126 relative to the smoke evacuation channel 148.

[0126] 17, the non-rotating fitting at the proximal end 148A of the smoke evacuation channel 148 can include a through bore 1774 having a smaller cross-sectional area than the cross-sectional area of ​​the body 148C of the smoke evacuation channel 148 proximal to the non-rotating fitting. The relatively smaller size of the through bore 1774 can help direct the smoke into a relatively smaller volume of space as it exits the proximal end 148A of the smoke evacuation channel 148. This can advantageously help reduce or prevent exposure of electrical components in the internal bore 125 of the handle 124 to smoke.

[0127] Figure 19 shows a partially exploded view of the assembly of light source 140, optical lens assembly 142 of Figures 5A-5B, and heat sink 1580 in smoke evacuation channel 148, according to one embodiment. Figure 20 shows the assembly of optical lens assembly 142 and electrosurgical electrode 128 shown in Figures 5A-5B.

[0128] 15-16 and 19-20, electrosurgical device 112 can include a light source 140 and an optical lens assembly 142 in shaft 126 of housing 123. As described above, light source 140 is configured to emit light into optical lens assembly 142, which is configured to transmit light distally from light source 140 and emit the light from distal end 126B of shaft 126.

[0129] As shown in FIG. 20 , electrosurgical electrode 128 has a longitudinal axis 2031 that extends between a proximal end of electrosurgical electrode 128 and a distal end of electrosurgical electrode 128. Light source 140 is disposed circumferentially about longitudinal axis 2031 of electrosurgical electrode 128. For example, as shown in FIG. 20 , lens aperture 411 may have a central axis that is collinear with longitudinal axis 2031 of electrosurgical electrode 128. Disposing light source 140 around the periphery of electrosurgical electrode 128 may help to distribute light around the entire circumference of electrosurgical electrode 128, which may help to reduce shadows and provide greater illumination uniformity at all rotational alignment positions of electrosurgical electrode 128 relative to handle 124 and / or electrosurgical device 112 relative to target tissue.

[0130] Additionally, the smoke evacuation channel 148 can extend through a lens opening 411 in the optical lens assembly 142 and a PCB opening 409 in the LED PCB 407. This can help center the smoke evacuation channel 148 in the shaft 126 (e.g., the central axis of the smoke evacuation channel 148 and the central axis of the shaft 126 can be collinear), which can enhance suction at the surgical site. In this arrangement, the electrosurgical device 112 can provide illumination and suction around the electrosurgical electrode 128. Furthermore, integrating the optical lens assembly 142 of Figures 3 and 5A-5B into this arrangement can improve the quality of illumination, reduce the size of the distal end of the electrosurgical device, and improve the line of sight to the surgical site.

[0131] In one embodiment, light source 140, optical lens assembly 142 and / or heat sink 1580 can be fixedly coupled to handle 124. In this arrangement, shaft 126 and electrosurgical electrode 128 can rotate about light source 140, optical lens assembly 142 and / or heat sink 1580. For example, light source 140, optical lens assembly 142 and / or heat sink 1580 can have a non-circular shape that can engage with a non-circular shape of body 148C of smoke evacuation channel 148 to prevent rotation of light source 140, optical lens assembly 142 and / or heat sink 1580 relative to handle 124 while shaft 126 and electrosurgical electrode 128 rotate relative to handle 124. In FIGS. 19-20, the non-circular shape is an ellipse. However, light source 140, optical lens assembly 142, heat sink 1580 and / or smoke evacuation channel 148 can have other non-circular shapes in other embodiments.

[0132] Additionally, in this arrangement, the light source 140, optical lens assembly 142 and heat sink 1580 can be telescopically movable relative to the handle 124 along with the shaft 126. As noted above, the housing conductors 134 and shaft conductors 136 can provide for electrically coupling the light source 140 to the DC power source 144 during such telescopic movement. As shown in FIG. 19 , the shaft 126 can include a positive-photoconductor 1536A and a negative-photoconductor 1536B that slidably engage corresponding conductors in the handle 124 during axial telescopic movement of the shaft 126 relative to the handle 124.

[0133]

[0023] Referring now to Figure 21, there is shown a cross-sectional view of the optical component 301 of the optical lens assembly 142 shown in Figure 3 according to one embodiment. As shown in Figure 21, the optical lens assembly 142 includes a proximal reflective surface 303 and a distal transmissive surface 305 having an aspheric shape. Additionally, Figure 21 shows the light source 140 housed in the cavity 415 of the optical component 301 at the proximal end 142A. Figure 21 further shows ray traces illustrating an exemplary light beam emitted by the light source 140 that is reflected and collimated by the proximal reflective surface 303 as the light beam propagates to the distal transmissive surface 305.

[0134] FIG. 22 shows an example optical output pattern for the optical lens assembly 142 shown in FIGS. 4A-4B, and FIG. 23 shows an example optical output pattern for the optical lens assembly 142 shown in FIGS. 5A-5B, according to an embodiment.

[0135] 24, a flow chart of a process 2400 for operating an electrosurgical device is shown, according to an embodiment. As shown in FIG. 24, the process 24 includes providing an electrosurgical device at block 2410. The electrosurgical device may include a housing having a proximal end and a distal end. The electrosurgical device may also include an electrosurgical electrode extending distally from the distal end of the housing, and a plurality of light sources in the housing. The multiple light sources may be configured to generate light.

[0136] Additionally, the electrosurgical device may include an optical lens assembly having a proximal end and a distal end. The optical lens assembly may include a plurality of optical components (i) coupled to one another at a distal end of the optical lens assembly and (ii) spaced apart from one another at a proximal end of the optical lens assembly. Each optical component is optically coupled to a respective light source of the plurality of light sources. Each optical component includes a proximal reflective surface extending distally from a respective light source optically coupled to the optical component and a distal transmitting surface at the distal end of the optical lens assembly. The proximal reflective surface is configured to reflect light emitted by the respective light source toward the distal end. The proximal reflective surface may have an aspheric shape configured to substantially collimate light reflected by the proximal reflective surface. The distal transmitting surface is configured to output light distally from the optical component.

[0137] At block 2412, process 2400 includes emitting light by a plurality of light sources. After emitting light at block 2412, process 2400 includes transmitting light through each optical component at block 2414 by (i) reflecting the light in a substantially collimated manner by a proximal reflective surface of the optical component toward a distal end at block 2416, and (ii) outputting the light in a distal direction by a distal transmitting surface of the optical component at block 2418.

[0138] 25-30 depict additional aspects of a process 2400 according to another embodiment. As shown in FIG. 25, process 2400 can also include delivering electrosurgical energy to an electrosurgical electrode at block 2420. In one embodiment, delivering electrosurgical energy to the electrosurgical electrode at block 2420 can occur while emitting light at block 2412.

[0139] As shown in Figure 26, reflecting the light by the proximal reflective surface at block 2416 can include reflecting the light by total internal reflection at block 2422. In the example shown in Figure 26, the proximal reflective surface can be a total internal reflection (TIR) ​​reflector.

[0140] In the embodiment shown in Figure 27, at the proximal end of the optical lens assembly, each optical component defines a cavity in which a respective light source is positioned such that the light sources are distal to a proximal-most surface of the optical lens assembly. As shown in Figure 27, emitting light at block 2412 can include emitting light from the light sources at a location distal to the proximal-most surface of the optical lens assembly at block 2424.

[0141] As shown in FIG. 28, emitting light at block 2412 can include emitting light from multiple light sources across a gap to a proximal reflective surface at block 2426.

[0142] As shown in FIG. 29, emitting light at block 2412 may include emitting light from multiple light sources equally spaced around the longitudinal axis of the electrosurgical electrode at block 2428.

[0143] As shown in FIG. 30, outputting light in a distal direction by the distal transmissive surfaces at block 2418 may include transmitting the light through an aspheric lens of each distal transmissive surface at block 2430.

[0144] As shown in FIG. 31, outputting light in a distal direction by the distal transmissive surfaces at block 2418 may include transmitting the light through a Fresnel lens of each distal transmissive surface at block 2432.

[0145] In the example shown in FIG. 32, the multiple light sources can include multiple light emitting diodes (LEDs) coupled to a printed circuit board (PCB). The PCB can also include a ring having a PCB opening. The electrosurgical device can include a suction tube extending through a PCB opening in the PCB and an opening in the optical lens assembly. The multiple light sources can be positioned around the circumference of the suction tube. A distal end of the optical lens assembly can extend around the circumference of the suction tube. As shown in FIG. 32, the process 2400 can also include applying a suction force to the suction tube at block 2434.

[0146] As shown in FIG. 33, outputting light in block 2418 may include outputting light in block 2436 at a plane distal to the distal end of the electrosurgical electrode such that the light emitted by the optical lens assembly has a substantially uniform intensity of light at each point in space.

[0147] As shown in FIG. 34, outputting light at block 2418 may include outputting light at block 2438 such that the light defines a light pattern in a plane distal to the distal end, and the intensity of the light at the weakest portion of the light pattern has an intensity that is at least 50 percent of the intensity of the light at the strongest portion of the light pattern.

[0148] The description of the different advantageous arrangements has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the embodiments in the disclosed form. Many modifications and variations will become apparent to those skilled in the art. Furthermore, different advantageous embodiments may describe different advantages over other advantageous embodiments. The selected embodiment or embodiments have been chosen and described to explain the principles, practical applications of the embodiments, and to enable others skilled in the art to understand the disclosure for the different embodiments with various modifications as suitable for the particular use envisaged.

[0149] It is also contemplated that any optional features of the described variations of the invention may be presented and claimed independently or in combination with any one or more of the features described herein. Similarly, reference to a singular item includes the possibility that there are multiple of the same items. More specifically, as used in this specification and the appended claims, the singular forms "a," "and," "said," and "the" include plural references unless the context clearly dictates otherwise. It is further noted that the claims may be written to exclude any optional elements. This statement is hereby intended to serve as a predicate for the use of such exclusive terms, such as "solely," "only," and the like, in connection with the reference of the claim elements, or the use of a "negative" limitation. Unless otherwise specified herein, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which the invention pertains. The breadth of this application is not limited by the subject specification, but only by the plain meaning of the claim terms employed. The technical ideas that can be understood from the above-described embodiments will be described below. [Aspect 1] 1. An electrosurgical device comprising: a housing having a proximal end and a distal end; an electrosurgical electrode extending distally from the distal end of the housing; a plurality of light sources in the housing configured to generate light; an optical lens assembly having a proximal end and a distal end; Equipped with the optical lens assembly includes a plurality of optical components: (i) coupled to one another at the distal end of the optical lens assembly; and (ii) spaced apart from one another at the proximal end of the optical lens assembly; each optical component is optically coupled to a respective light source of the plurality of light sources; Each optical component is a proximal reflective surface extending distally from each of the light sources optically coupled to the optical component, the proximal reflective surface configured to reflect light emitted by each of the light sources toward the distal end, the proximal reflective surface having an aspheric shape configured to substantially collimate light reflected by the proximal reflective surface; a distal transmitting surface at the distal end of the optical lens assembly, the distal transmitting surface configured to output the light from the optical component in the distal direction; and An electrosurgical device comprising: [Aspect 2] The electrosurgical device of embodiment 1, wherein the proximal reflective surface comprises a total internal reflection (TIR) ​​reflector. [Aspect 3] An electrosurgical device as described in aspect 2, wherein the proximal reflective surface and the housing are spaced apart from one another such that an air gap surrounds the proximal reflective surface. [Aspect 4] An electrosurgical device described in any one of aspects 1 to 3, wherein at the proximal end of the optical lens assembly, each optical component defines a cavity in which each of the multiple light sources is disposed such that the multiple light sources are distal to a proximal-most surface of the optical lens assembly. [Aspect 5] An electrosurgical device as described in aspect 4, wherein each optical component is separated from its respective light source optically coupled to the optical component by an air gap. [Aspect 6] the electrosurgical electrode having a longitudinal axis extending between a proximal end of the electrosurgical electrode and a distal end of the electrosurgical electrode; The electrosurgical device of any one of aspects 1 to 5, wherein the plurality of light sources are circumferentially arranged around the longitudinal axis of the electrosurgical electrode. [Aspect 7] 7. The electrosurgical device of embodiment 6, wherein the plurality of light sources consists of three light sources equally spaced around the longitudinal axis of the electrosurgical electrode. [Aspect 8] An electrosurgical device as described in aspect 6, wherein the optical lens assembly defines an opening having a central axis collinear with the longitudinal axis of the electrosurgical electrode. [Aspect 9] The electrosurgical device of any one of aspects 1 to 8, wherein each distal transmitting surface is an aspheric lens. [Aspect 10] The electrosurgical device of any one of aspects 1 to 8, wherein each distal transmitting surface is a Fresnel lens. [Aspect 11] the Fresnel lens having a flat surface at a distal end; the flat surface at the distal end defines a plurality of concentric rings; Each ring has its own optical properties; 11. An electrosurgical device as described in aspect 10, wherein the optical properties of the multiple rings differ from one another such that the flat surface at the distal end transmits light in a manner approximating an aspheric lens. [Aspect 12] An electrosurgical device as described in aspect 11, wherein the flat surface at the distal end includes a plurality of lenslets. [Aspect 13] the optical lens assembly having an inner surface and an outer surface; the inner surface defines a through hole; An electrosurgical device described in any one of aspects 1 to 12, wherein between the proximal reflective surface and the distal transmissive surface, a cross-section of the optical lens assembly has a non-circular shape on the inner surface and a circular shape on the outer surface. [Aspect 14] 14. The electrosurgical device of claim 13, wherein the non-circular shape is an ellipse. [Aspect 15] An electrosurgical device described in any one of aspects 1 to 14, wherein less than about 10% of light from one optical lens component of the plurality of optical components passes through an adjacent optical lens component of the plurality of optical components. [Aspect 16] An electrosurgical device as described in aspect 15, wherein a portion of the light emitted by one of the plurality of optical components overlaps with a portion of the light emitted by another one of the plurality of optical components. [Aspect 17] The housing comprises: a handle having a proximal end and a distal end; a shaft extending from the distal end of the housing; Equipped with The electrosurgical device of any one of aspects 1 to 16, wherein the electrosurgical electrode extends from the distal end of the shaft and the multiple light sources are within the shaft. [Aspect 18] the shaft comprising a tube and a sleeve structure extending distally from the tube; the sleeve structure extends around the optical lens assembly; An electrosurgical device as described in embodiment 17, wherein each distal permeable surface is distal to the distal-most end of the sleeve structure. [Aspect 19] the plurality of light sources includes a plurality of light emitting diodes (LEDs) coupled to a printed circuit board (PCB); 18. An electrosurgical device as described in embodiment 17, wherein the PCB includes a ring having a PCB opening. [Aspect 20] An electrosurgical device as described in embodiment 19, wherein each LED comprises a die and a protective layer. [Aspect 21] 20. The electrosurgical device of embodiment 19, wherein each LED has a diameter of about 1 millimeter (mm) to about 2 mm. [Aspect 22] a suction tube extending through the PCB opening in the PCB and through an opening in the optical lens assembly; The plurality of light sources are arranged around the suction tube; 20. The electrosurgical device of claim 19, wherein the distal end of the optical lens assembly extends around the suction tube. [Aspect 23] An electrosurgical device described in any one of aspects 1 to 22, wherein in a plane distal to the distal end of the electrosurgical electrode, the light emitted by the optical lens assembly has a substantially uniform light intensity at each point in space. [Aspect 24] light emitted by the optical lens assembly defines a light pattern at the plane distal to the distal end; 24. An electrosurgical device as described in aspect 23, wherein the light intensity in the weakest portion of the light pattern has an intensity that is at least 50 percent of the light intensity in the strongest portion of the light pattern. [Aspect 25] a housing having a proximal end and a distal end; an electrosurgical electrode extending distally from the distal end of the housing; a plurality of light sources in the housing configured to generate light; an optical lens assembly having a proximal end and a distal end; Equipped with the optical lens assembly includes a plurality of optical components: (i) coupled to one another at the distal end of the optical lens assembly; and (ii) spaced apart from one another at the proximal end of the optical lens assembly; each optical component is optically coupled to a respective light source of the plurality of light sources; Each optical component is (a) a proximal reflective surface extending distally from each of the light sources optically coupled to the optical component, the proximal reflective surface configured to reflect light emitted by each of the light sources toward the distal end, the proximal reflective surface having an aspheric shape configured to substantially collimate light reflected by the proximal reflective surface; (b) a distal transmitting surface at the distal end of the optical lens assembly, the distal transmitting surface configured to output the light from the optical component in the distal direction; and 1. A method of using an electrosurgical device comprising: providing the electrosurgical device; emitting light by said plurality of light sources; After emitting the light, reflecting the light in a substantially collimated manner by the proximal reflective surface of the optical component toward the distal end; and outputting the light in the distal direction by the distal transmissive surface of the optical component; transmitting the light through each optical component by A method comprising: [Aspect 26] 26. The method of embodiment 25, further comprising supplying electrosurgical energy to the electrosurgical electrode. [Aspect 27] 27. The method of embodiment 26, wherein supplying electrosurgical energy to the electrosurgical electrode occurs while emitting the light. [Aspect 28] the proximal reflective surface comprises a total internal reflection (TIR) ​​reflector; The method of any one of embodiments 25 to 27, wherein reflecting the light by the proximal reflective surface comprises reflecting the light by total internal reflection. [Aspect 29] at the proximal end of the optical lens assembly, each optical component defines a cavity in which a respective one of the plurality of light sources is disposed such that the light sources are distal to a proximal-most surface of the optical lens assembly; A method according to any one of aspects 25 to 28, wherein emitting the light includes emitting light from the multiple light sources at a location distal to a most proximal surface of the optical lens assembly. [Aspect 30] 30. The method of embodiment 29, wherein emitting the light includes emitting the light from the multiple light sources across a gap to the proximal reflective surface. [Aspect 31] The method of any one of aspects 25 to 30, wherein emitting the light includes emitting the light from the multiple light sources equally spaced around the longitudinal axis of the electrosurgical electrode. [Aspect 32] A method according to any one of aspects 25 to 31, wherein outputting the light in the distal direction by the distal transmitting surfaces includes transmitting the light through an aspheric lens of each distal transmitting surface. [Aspect 33] The method of any one of embodiments 25 to 31, wherein outputting the light in the distal direction by the distal transmitting surfaces includes transmitting the light through a Fresnel lens of each distal transmitting surface. [Aspect 34] the plurality of light sources includes a plurality of light emitting diodes (LEDs) coupled to a printed circuit board (PCB); the PCB includes a ring having a PCB opening, the electrosurgical device includes a suction tube extending through the PCB opening in the PCB and an opening in the electro-optical lens assembly; The plurality of light sources are arranged around the suction tube; the distal end of the optical lens assembly extends around the aspiration tube; The method of any one of aspects 25 to 33, wherein the method further comprises applying a suction force to the suction tube. [Aspect 35] The method of any one of aspects 25 to 34, wherein outputting the light includes outputting the light such that in a plane distal to the distal end of the electrosurgical electrode, the light emitted by the optical lens assembly has a substantially uniform light intensity at each point in space. [Aspect 36] The method of claim 35, wherein outputting the light includes outputting the light such that the light defines a light pattern at the plane distal to the distal end, and the intensity of the light at the weakest portion of the light pattern has an intensity that is at least 50 percent of the intensity of the light at the strongest portion of the light pattern.

Claims

1. 1. An electrosurgical device comprising: a housing having a proximal end and a distal end; an electrosurgical electrode extending distally from the distal end of the housing; a plurality of light sources in the housing configured to generate light; an optical lens assembly having a proximal end and a distal end; Equipped with the optical lens assembly includes a plurality of optical components: (i) coupled to one another at the distal end of the optical lens assembly; and (ii) spaced apart from one another at the proximal end of the optical lens assembly; each optical component is optically coupled to a respective light source of the plurality of light sources; Each optical component is a proximal reflective surface extending distally from each of the light sources optically coupled to the optical component, the proximal reflective surface configured to reflect light emitted by each of the light sources toward the distal end, the proximal reflective surface having an aspheric shape configured to substantially collimate light reflected by the proximal reflective surface; a distal transmitting surface at the distal end of the optical lens assembly, the distal transmitting surface configured to output the light from the optical component in the distal direction; and Equipped with At the proximal end of the optical lens assembly, each optical component defines a cavity in which each of the multiple light sources is disposed such that the multiple light sources are distal to a proximal-most surface of the optical lens assembly.

2. The electrosurgical device of claim 1 , wherein the proximal reflective surface comprises a total internal reflection (TIR) ​​reflector, and the proximal reflective surface and the housing are spaced apart from one another such that an air gap surrounds the proximal reflective surface.

3. An electrosurgical device as described in claim 1 or claim 2, wherein each optical component is separated from its respective light source optically coupled to the optical component by a gap.

4. The electrosurgical electrode having a longitudinal axis extending between a proximal end of the electrosurgical electrode and a distal end of the electrosurgical electrode; the plurality of light sources are circumferentially disposed about the longitudinal axis of the electrosurgical electrode; the optical lens assembly defines an aperture having a central axis collinear with the longitudinal axis of the electrosurgical electrode. An electrosurgical device according to any one of claims 1 to 3.

5. An electrosurgical device as described in any one of claims 1 to 4, wherein each distal transmitting surface is an aspheric lens.

6. Each distal transmitting surface is a Fresnel lens; the Fresnel lens having a flat surface at a distal end; the flat surface at the distal end defines a plurality of concentric rings; Each ring has its own optical properties; the optical properties of the rings differ from one another such that the flat surface at the distal end transmits light in a manner approximating an aspheric lens; An electrosurgical device according to any one of claims 1 to 4.

7. The optical lens assembly, comprising an inner surface and an outer surface; the inner surface defines a through hole; An electrosurgical device according to any one of claims 1 to 6, wherein between the proximal reflective surface and the distal transmissive surface, a cross-section of the optical lens assembly has a non-circular shape on the inner surface and a circular shape on the outer surface.

8. wherein less than about 10% of the light from one optical lens component of the plurality of optical components passes through an adjacent optical lens component of the plurality of optical components; a portion of the light emitted by one of the plurality of optical components overlaps with a portion of the light emitted by another of the plurality of optical components; An electrosurgical device according to any one of claims 1 to 7.

9. The plurality of light sources includes a plurality of light emitting diodes (LEDs) coupled to a printed circuit board (PCB); the PCB includes a ring having a PCB opening; Each LED comprises a die and a protective layer; An electrosurgical device according to any one of claims 1 to 8.

10. The electrosurgical electrode of claim 1, wherein in a plane distal to the distal end of the electrosurgical electrode, the light emitted by the optical lens assembly has a substantially uniform light intensity at each point in space; light emitted by the optical lens assembly defines a light pattern at the plane distal to the distal end; the light intensity in the weakest portion of the light pattern has an intensity that is at least 50 percent of the light intensity in the strongest portion of the light pattern; An electrosurgical device according to any one of claims 1 to 9.

Images