Electrosurgical tool, method of use, and method of manufacturing

Abstract

In an example, an electrosurgical tool includes a handle defining an interior cavity, a power cord configured to be coupled to and receive electrosurgical energy from an electrosurgical generator, and a shaft extending distally from the interior cavity of the handle. The shaft defines an interior bore. The electrosurgical tool also includes a printed circuit board located in the internal bore of the shaft. The printed circuit board is electrically connected to the power line. The printed circuit board is configured to conduct electrosurgical energy from the power cord to an interior surface of the shaft. The shaft is movable relative to the handle and the printed circuit board. The electrosurgical tool also includes an electrosurgical electrode extending distally from the distal end of the shaft. The shaft is configured to conduct electrosurgical energy to the electrosurgical electrode.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of priority to U.S. Provisional Application No. 63 / 342,611, filed on May 16, 2022, the entire contents of which are incorporated herein by reference. Technical Field

[0003] The present disclosure relates generally to electrosurgery and, more particularly, to electrosurgical tools and methods of transmitting electrosurgical energy via electrosurgical tools. Background Art

[0004] Electrosurgery involves applying radio frequency (RF) current (also known as electrosurgical energy) to biological tissue to cut, coagulate, or alter the biological tissue during an electrosurgical procedure. Specifically, an electrosurgical generator generates an electrical current and provides it to an active electrode, which applies the current (and therefore power) to the tissue. The current passes through the tissue and returns to the generator through a return electrode (also known as a "dispersive electrode"). As the current passes through the tissue, the impedance of the tissue converts a portion of the current into heat energy (e.g., through the principles of resistive heating), which raises the temperature of the tissue and causes a change in the tissue (e.g., cutting, coagulating, ablating, and / or sealing the tissue). Summary of the invention

[0005] In an example, an electrosurgical tool includes a handle defining an internal cavity, a power cord configured to be connected to an electrosurgical generator and receive electrosurgical energy from the electrosurgical generator, and a shaft extending distally from the internal cavity of the handle. The shaft defines an internal hole. The electrosurgical tool also includes a printed circuit board located in the internal hole of the shaft. The printed circuit board is electrically connected to the power cord. The printed circuit board is configured to conduct electrosurgical energy from the power cord to an internal surface of the shaft. The shaft is movable relative to the handle and the printed circuit board. The electrosurgical tool also includes an electrosurgical electrode extending distally from a distal end of the shaft. The shaft is configured to conduct electrosurgical energy to the electrosurgical electrode.

[0006] In another example, a method of operating an electrosurgical tool includes coupling a power cord of the electrosurgical tool to an electrosurgical generator. The electrosurgical tool includes a handle defining an internal cavity, and a shaft extending distally from the internal cavity of the handle. The shaft defines an internal hole. The electrosurgical tool also includes a printed circuit board located in the internal hole of the shaft. The printed circuit board is electrically coupled to the power cord. The printed circuit board is configured to conduct electrosurgical energy from the power cord to an internal surface of the shaft. The shaft is movable relative to the handle and the printed circuit board. The electrosurgical tool also includes an electrosurgical electrode extending distally from a distal end of the shaft.

[0007] The method also includes supplying electrosurgical energy from the electrosurgical generator to the printed circuit board using the power cord. In addition, the method includes supplying electrosurgical energy from the power cord to the interior surface of the shaft through the printed circuit board. The method also includes conducting the electrosurgical energy from the shaft to the electrosurgical electrode.

[0008] In another example, a method of manufacturing an electrosurgical tool includes forming a housing including a handle defining an interior cavity and a shaft extending distally from the interior cavity of the handle. The shaft defines an interior hole. The method also includes positioning a printed circuit board in the interior hole of the shaft and electrically coupling the printed circuit board to a power cord. The power cord is configured to be coupled to an electrosurgical generator and receive electrosurgical energy from the electrosurgical generator. The shaft is movable relative to the handle and the printed circuit board. The method also includes electrically coupling the printed circuit board to an interior surface of the shaft, and electrically coupling an electrosurgical electrode to a distal end of the shaft. The shaft is configured to conduct the electrosurgical energy to the electrosurgical electrode. BRIEF DESCRIPTION OF THE DRAWINGS

[0009] The novel features believed to be characteristic of the illustrative examples are set forth in the appended claims. However, the illustrative examples together with the preferred mode of use, further objects and description will be best understood by reference to the following detailed description of illustrative examples of the present disclosure when read in conjunction with the accompanying drawings.

[0010] Figure 1 Depicted is a simplified block diagram of an electrosurgical system according to an example.

[0011] Figure 2 A partial cross-sectional view of an electrosurgical tool according to an example is shown.

[0012] Figure 3 Depicted is a perspective view of an electrosurgical tool according to an example.

[0013] Figure 4 Depicted according to the example Figure 3 A cross-sectional view of an electrosurgical tool is shown.

[0014] Figure 5 Depicted according to the example Figure 3 A partial cross-sectional view of the shaft of an electrosurgical tool is shown.

[0015] Figure 6 Depicted is a diagram according to another example Figure 3 A partial cross-sectional view of the shaft of the electrosurgical tool shown in .

[0016] Fig. 7A Depicted is a first side view of a printed circuit board according to an example.

[0017] Figure 7B Depicted according to the example Fig. 7A A second side view of a printed circuit board is shown.

[0018] Figure 8 A printed circuit board according to another example is depicted.

[0019] Fig. 9 Depicted is an enlarged cross-sectional view of a distal end of a shaft and an electrosurgical electrode according to an example.

[0020] Fig.10 A perspective view of a smoke exhaust channel and a shaft of an electrosurgical tool is shown according to an example.

[0021] Fig.11 A side view of a smoke exhaust channel and a shaft of an electrosurgical tool is shown according to an example.

[0022] Fig.12 A partially exploded view of an assembly of a printed circuit board, light source, optical structure, heat sink, and smoke exhaust passage of an electrosurgical tool according to an example is shown.

[0023] Fig.13 Depicted are an end portion of a printed circuit board, an optical structure, and an assembly of an electrosurgical electrode according to an example.

[0024] Fig.14 Depicted is a side view of an electrosurgical tool according to an example, with a first portion of a handle omitted for illustrative purposes.

[0025] Fig.15 Depicted according to the example Fig.14 A first perspective view of an electrosurgical tool is shown with the second portion of the handle omitted for illustrative purposes.

[0026] Fig.16 Depicted according to the example Fig.14 A second perspective view of the electrosurgical tool is shown with the second portion of the handle omitted for illustrative purposes.

[0027] Fig.17 Depicted according to the example Fig.14 The electrosurgical tool is shown with the first and second portions of the handle omitted for illustration purposes.

[0028] Fig.18 Depicted according to the example Fig.14 An exploded view of the stop assembly of an electrosurgical tool is shown.

[0029] Fig.19 Depicted according to the example Fig.14 A shaft stop of a stop assembly of an electrosurgical tool is shown.

[0030] Fig. 20 Depicted according to the example Fig.14A partial cross-sectional view of the connection between the shaft stop and the shaft of an electrosurgical tool is shown.

[0031] Fig.21 Depicted according to the example Fig.14 The rotating nut of the electrosurgical tool is shown.

[0032] Fig. 22 A flow chart of a process for operating an electrosurgical tool according to an example is depicted.

[0033] Fig.23 A flowchart of a process for operating an electrosurgical tool according to an example is depicted, which process may be at least Fig. 22 Use the procedure shown in .

[0034] Fig.24 A flowchart of a process for operating an electrosurgical tool according to an example is depicted, which process may be at least Fig. 22 Use the procedure shown in .

[0035] Fig.25 A flowchart of a process for operating an electrosurgical tool according to an example is depicted, which process may be at least Fig. 22 Use the procedure shown in .

[0036] Fig.26 A flowchart of a process for operating an electrosurgical tool according to an example is depicted, which process may be at least Fig. 22 Use the procedure shown in .

[0037] Fig. 27 A flowchart of a process for operating an electrosurgical tool according to an example is depicted, which process may be at least Fig. 22 Use the procedure shown in .

[0038] Fig.28 A flowchart of a process for operating an electrosurgical tool according to an example is depicted, which process may be at least Fig. 22 Use the procedure shown in .

[0039] Fig.29 A flowchart of a process for operating an electrosurgical tool according to an example is depicted, which process may be at least Fig. 22 Use the procedure shown in .

[0040] Fig.30 A flowchart of a process for operating an electrosurgical tool according to an example is depicted, which process may be at least Fig. 22 Use the procedure shown in .

[0041] Fig.31 A flowchart of a process for operating an electrosurgical tool according to an example is depicted, which process may be at least Fig. 22 Use the procedure shown in .

[0042] Fig.32 A flowchart of a process for operating an electrosurgical tool according to an example is depicted, which process may be at least Fig. 22 Use the procedure shown in .

[0043] Fig.33 A flowchart of a process for operating an electrosurgical tool according to an example is depicted, which process may be at least Fig. 22 Use the procedure shown in .

[0044] Fig.34 Depicted is a flow chart of a process for manufacturing an electrosurgical tool according to an example.

[0045] Fig.35 A flow chart of a process for manufacturing an electrosurgical tool according to an example is depicted, the process being at least Fig.34 Use the procedure shown in .

[0046] Fig.36 A flow chart of a process for manufacturing an electrosurgical tool according to an example is depicted, the process being at least Fig.34 Use the procedure shown in .

[0047] Fig.37 A flow chart of a process for manufacturing an electrosurgical tool according to an example is depicted, the process being at least Fig.34 Use the procedure shown in .

[0048] Fig.38 A flow chart of a process for manufacturing an electrosurgical tool according to an example is depicted, the process being at least Fig.34 Use the procedure shown in .

[0049] Fig.39 A flow chart of a process for manufacturing an electrosurgical tool according to an example is depicted, the process being at least Fig.34 Use the procedure shown in .

[0050] Fig.40 A flow chart of a process for manufacturing an electrosurgical tool according to an example is depicted, the process being at least Fig.34 Use the procedure shown in .

[0051] Fig.41 A flow chart of a process for manufacturing an electrosurgical tool according to an example is depicted, the process being at least Fig.34 Use the procedure shown in .

[0052] Fig.42 A flow chart of a process for manufacturing an electrosurgical tool according to an example is depicted, the process being at least Fig.34 Use the procedure shown in .

[0053] Fig.43 A flow chart of a process for manufacturing an electrosurgical tool according to an example is depicted, the process being at least Fig.34 Use the procedure shown in .

[0054] Fig.44 A flow chart of a process for manufacturing an electrosurgical tool according to an example is depicted, the process being at least Fig.34 Use the procedure shown in .

[0055] Fig.45 A flow chart of a process for manufacturing an electrosurgical tool according to an example is depicted, the process being at least Fig.34 Use the procedure shown in .

[0056] Fig.46 Depicted is a cross-sectional view of an electrosurgical tool through a handle, a shaft stop, and a rotation nut according to another example. DETAILED DESCRIPTION

[0057] The disclosed examples will now be described more fully in conjunction with the accompanying drawings, in which some but not all of the disclosed examples are shown. In fact, several different examples may be described, and they should not be construed as limited to the examples set forth herein. Rather, these examples are described to make the disclosure thorough and complete and to fully convey the scope of the disclosure to those skilled in the art.

[0058] For the quantities (values) or measurements described herein, the term "about" or "substantially" means that the described features, parameters or values ​​do not need to be achieved precisely, but deviations or changes may occur, including, for example, tolerances, measurement errors, measurement accuracy limitations, and other factors known to those skilled in the art, but these deviations or changes will not hinder the effect that the feature is intended to provide.

[0059] As described above, an electrosurgical tool can apply electrosurgical energy from an electrosurgical electrode to tissue using electrical energy provided by an electrosurgical generator. Thus, an electrosurgical tool typically includes a housing in which one or more conductors are disposed for supplying electrosurgical energy to the electrosurgical electrode. Some electrosurgical tools include a shaft that is axially adjustable relative to the housing (e.g., the shaft can be telescopically movable relative to the housing). This can facilitate adjustment of the length of the electrosurgical tool to treat target tissues of different sizes and / or shapes.

[0060] Additionally, some electrosurgical instruments provide for rotation of the electrosurgical electrode relative to the housing. This can facilitate adjustment of the angle of the electrosurgical electrode relative to one or more user input devices of the electrosurgical instrument. In such an arrangement, a user can comfortably hold the housing so that the fingers can comfortably operate the user input device while the electrosurgical electrode is set in a rotational position selected from a plurality of rotational positions relative to the housing based on, for example, the location, size, and / or shape of the surgical site being operated on by the user.

[0061] However, providing for axial movement and / or rotation of the electrosurgical electrode relative to the housing can increase design complexity and manufacturing costs. For example, it can be challenging to maintain electrical connections between electrical components in the housing and the electrosurgical electrode as the electrosurgical electrode rotates relative to the housing and / or moves axially relative to the housing. This problem can be further exacerbated when the electrosurgical tool includes other features distal to the housing (e.g., a light source, one or more optical components, and / or a smoke exhaust feature).

[0062] The present application provides an electrosurgical tool, a method for using an electrosurgical tool, and a method for manufacturing an electrosurgical tool that can address at least some of the above challenges. For example, in one example, the electrosurgical tool may include a printed circuit board located in an internal hole of a shaft that extends distally from an inner cavity of a housing. The printed circuit board can conduct electrosurgical energy from a power cord to an inner surface of the shaft. The shaft can be movable relative to the housing and the printed circuit board. An electrosurgical electrode can extend distally from a distal end of the shaft and receive electrosurgical energy from the shaft. In this arrangement, the printed circuit board and the shaft can maintain an electrical connection between the electrosurgical electrode and an electrosurgical energy source (e.g., an electrosurgical generator) in multiple rotational orientations and / or axial positions of the electrosurgical electrode relative to the housing.

[0063] Reference now Figure 1 , shows an electrosurgical system 100 according to an example. Figure 1 As shown, the electrosurgical system 100 includes an electrosurgical generator 110 and an electrosurgical tool 112. Generally speaking, the electrosurgical generator 110 can generate electrosurgical energy suitable for performing electrosurgery on a patient. For example, the electrosurgical generator 110 can include a power converter circuit 114 that can convert grid power into electrosurgical energy, such as radio frequency (RF) output power. As an example, the power converter circuit 114 can include one or more electrical components (e.g., one or more transformers) that can control the voltage, current, and / or frequency of the electrosurgical energy.

[0064] In an example, the 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. As an example, the user interface 116 may include one or more buttons, one or more switches, one or more dials, one or more keyboards, 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.

[0065] In an example, the user interface 116 may be operable to select an operating mode from a plurality of operating modes of the electrosurgical generator 110. As an example, the operating modes may include a cutting mode, a coagulation mode, an ablation mode, and / or a sealing mode. Combinations of these waveforms may also be formed to create hybrid modes. In one embodiment, the operating modes may correspond to corresponding waveforms of electrosurgical energy. Thus, in this embodiment, the electrosurgical generator 110 may 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.

[0066] The electrosurgical generator 110 may also include one or more generator sensors 118 that may sense one or more conditions associated with the electrosurgical energy and / or the target tissue. As an example, the generator sensor 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 an example, additionally or alternatively, the electrosurgical generator 110 may generate electrosurgical energy having an amount of electrosurgical energy (e.g., electrical power) and / or a waveform selected from the plurality of waveforms based on one or more parameters associated with the conditions sensed by the generator sensor 118.

[0067] In one example, the electrosurgical energy may have a frequency greater than about 100 kilohertz (kHz) to reduce (or avoid) irritation of muscles and / or nerves near the target tissue. In another example, the electrosurgical energy may have a frequency between about 300 kHz and about 500 kHz.

[0068] exist Figure 1 1 , the electrosurgical generator 110 also includes a connector 120 that can facilitate coupling the electrosurgical generator 110 to an electrosurgical tool 112. For example, the electrosurgical tool 112 can include a power cord 122 having a plug that can be coupled to a receptacle of the connector 120 of the electrosurgical generator 110. In this arrangement, the electrosurgical generator 110 can supply electrosurgical energy to the electrosurgical tool 112 through the coupling between the connector 120 of the electrosurgical generator 110 and the power cord 122 of the electrosurgical tool 112.

[0069] The electrosurgical generator 110 may also include a controller 141 that may control the operation of the electrosurgical generator 110. In examples, the controller 141 may be implemented using hardware, software, and / or firmware. For example, the controller 141 may include one or more processors and a non-transitory computer-readable medium (e.g., volatile and / or non-volatile memory) storing machine language instructions or other executable instructions. These instructions, when executed by the one or more processors, cause the electrosurgical generator 110 to perform various operations described herein. Thus, the controller 141 may receive data and store the data in memory. As shown in FIG. Figure 1 As shown, controller 141 may be communicatively coupled to power converter circuit 114 , user interface 116 , generator sensor 118 , and / or connector 120 .

[0070] like Figure 1 As shown, the electrosurgical tool 112 may include a housing 123. The housing 123 may be an elongated structure in which and / or on which the components of the electrosurgical tool 112 may be disposed. In some examples, the housing 123 may be an integral, one-piece, unitary structure. In other examples, the housing 123 may include a plurality of interconnected structures.

[0071] exist Figure 1 In the embodiment, the housing 123 includes a housing 252 (e.g., Figure 2 and Figure 4 ) and extending in a distal direction from the handle 124 and defining an internal hole 254 (e.g., as shown in Figure 2 and Figure 4 124, and a monopolar electrosurgical electrode 128 extending in a distal direction from the shaft 126. In general, the handle 124 may be configured to facilitate a user to grasp and manipulate the electrosurgical tool 112 when performing an electrosurgical procedure. For example, the handle 124 may have a shape and / or size that facilitates a user to perform an electrosurgical procedure by manipulating the electrosurgical tool 112 with one hand. In one embodiment, the handle 124 may have a shape and / or size that facilitates a user to hold the electrosurgical tool 112 in a writing utensil grip (e.g., the electrosurgical tool 112 may be an electrosurgical pencil).

[0072] In addition, for example, the handle 124 and / or the shaft 126 can include one or more electrical insulator materials (e.g., plastic materials). This can be advantageous in isolating the user from the electrosurgical energy flowing through the electrosurgical tool 112 when performing an electrosurgical procedure. As described in further detail below, at least a portion of the shaft 126 is formed of a conductive material so that the shaft 126 can conduct the electrosurgical energy to the monopolar electrosurgical electrode 128.

[0073] In some embodiments, the shaft 126 can be coupled to the handle 124 in a fixed and immovable manner. This can simplify manufacturing and reduce manufacturing costs, for example, by simplifying electrical connections (e.g., by omitting slip ring electrical contacts and / or sliding electrical contacts), which otherwise may need to take into account the movement of the shaft 126 and the handle 124 relative to each other. In one example, the handle 124 and the shaft 126 can be formed as a single integral structure so that the shaft 126 and the handle 124 are fixed and immovable relative to each other. In another example, the handle 124 and the shaft 126 can be fixedly coupled together by welding, bonding, and / or another coupling method that prevents movement between the handle 124 and the shaft 126.

[0074] In other embodiments, the shaft 126 can be movable relative to the handle 124 along the longitudinal axis of the electrosurgical tool 112. For example, the shaft 126 can be telescopically movable within the internal cavity 252 defined by the handle 124 so that the shaft 126 is extended in the distal direction relative to the handle 124 and retracted in the proximal direction (e.g., movable along the longitudinal axis of the electrosurgical tool 112). The monopolar electrosurgical electrode 128 is coupled to the shaft 126, and thus, the monopolar electrosurgical electrode 128 can be moved in an axial direction along the longitudinal axis relative to the handle 124 along with the shaft 126. This can be used to adjust the length of the electrosurgical tool 112, thereby facilitating electrosurgery at multiple different depths within the tissue (e.g., due to different anatomical shapes and / or sizes of the patient) and / or at multiple different angles.

[0075] In some embodiments, additionally or alternatively, the monopolar electrosurgical electrode 128 can be rotatable about a rotational axis that is parallel to the longitudinal axis of the electrosurgical tool 112. In some examples, the monopolar electrosurgical electrode 128 can be rotatable relative to the handle 124 and the shaft 126. In other examples, the monopolar electrosurgical electrode 128 can be rotationally fixed (non-rotatably) relative to the shaft 126, such that the shaft 126 and the monopolar electrosurgical electrode 128 can rotate together relative to the handle 124. Rotating the monopolar electrosurgical electrode 128 relative to the handle 124 can facilitate adjusting the angle of the monopolar electrosurgical electrode 128 relative to one or more user input devices 130 of the electrosurgical tool 112. In this arrangement, the user can comfortably hold the handle 124 in a position where their fingers can comfortably operate the user input device 130, while the monopolar electrosurgical electrode 128 is set in a rotational position selected from a plurality of rotational positions relative to the handle 124 based on, for example, the location, size, and / or shape of the surgical site on which the user is operating.

[0076] In one embodiment, the monopolar electrosurgical electrode 128 can rotate more than 360 degrees relative to the handle 124. This can improve ease of use by allowing the operator to freely rotate the monopolar electrosurgical electrode 128 without restriction. However, in other embodiments, the monopolar electrosurgical electrode 128 can rotate less than or equal to 360 degrees (e.g., 180 degrees or 360 degrees). This can still allow the operator to achieve the desired rotational arrangement orientation, but the operator may rotate in a first direction, reach a stop point that limits further rotation, and then rotate back in a second direction to achieve the desired rotational arrangement orientation.

[0077] While it may be beneficial 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 manufacturing and reduce manufacturing costs by, for example, simplifying electrical connections (e.g., by omitting slip ring electrical contacts and / or sliding electrical contacts) that may otherwise need to account for movement of the shaft 126 and handle 124 relative to each other.

[0078] The user input device 130 may select between operating modes of the electrosurgical tool 112 and / or the electrosurgical generator 110. For example, in one embodiment, the user input device 130 may be configured to select between a cutting operating mode and a coagulation operating mode. In response to actuation of the user input device 130 of the electrosurgical tool 112, the electrosurgical tool 112 may (i) receive electrosurgical energy having a power level and / or waveform corresponding to the operating mode selected by the user input device 130, and (ii) supply electrosurgical energy to the monopolar electrosurgical electrode 128.

[0079] exist Figure 1 , the electrosurgical tool 112 includes a plurality of electrical components that facilitate supplying electrosurgical energy received by the electrosurgical tool 112 from the electrosurgical generator 110 to the monopolar electrosurgical electrode 128. For example, at least a portion of the shaft 126 is formed of a conductive material so that the shaft 126 is electrically coupled to the monopolar electrosurgical electrode 128. In one embodiment, the shaft 126 can be formed entirely of a conductive material. For example, the shaft 126 can be a tubular structure formed entirely of metal. In another embodiment, the shaft 126 can include a conductive portion and an insulator portion, as long as the conductive portion is configured to conduct electrosurgical energy to the monopolar electrosurgical electrode 128.

[0080] In addition, the electrosurgical tool 112 includes a printed circuit board 132 (e.g., a flexible printed circuit board) in the internal bore 254 of the shaft 126 and / or the internal cavity 252 of the handle 124. The printed circuit board 132 can be electrically coupled to the power cord 122 and the shaft 126, which is electrically coupled to the monopolar electrosurgical electrode 128. In this arrangement, the printed circuit board 132 and the shaft 126 provide a circuit for conducting electrosurgical energy from the power cord 122 to the monopolar electrosurgical electrode 128.

[0081] As described in further detail below, the electrosurgical tool 112 may include one or more components that can help maintain an electrical connection between the printed circuit board 132 and an interior surface of the shaft 126 (and therefore, the monopolar electrosurgical electrode 128) in multiple axial positions of the shaft 126 relative to the handle 124 and / or in multiple rotational orientations of the shaft 126 relative to the handle 124 (e.g., in all axial positions when the shaft 126 is telescopically moved relative to the handle 124 and / or in all rotational orientations when the shaft 126 is rotated relative to the handle 124).

[0082] In an example, the user input device 130 may include one or more buttons on an outer surface of the handle 124. Each button of the user input device 130 may be operable to actuate a corresponding one of a plurality of switches 138 of the printed circuit board 132. In general, the switches 138 and / or the printed circuit board 132 are operable to control the supply of electrosurgical energy from the electrosurgical generator 110 to the monopolar electrosurgical electrode 128. For example, in one embodiment, when each button is operated (e.g., pressed), the corresponding switch 138 associated with the button may be actuated, causing the printed circuit board 132 to transmit a signal to the electrosurgical generator 110 and causing the electrosurgical generator 110 to responsively supply electrosurgical energy having a power level and / or waveform corresponding to the operating mode associated with the button. In another embodiment, operating the button and thereby actuating the corresponding switch 138 associated with the button may close the switch 138 to completely close the circuit to the electrosurgical generator 110, thereby causing the electrosurgical generator 110 to responsively provide electrosurgical energy having a power level and / or waveform corresponding to the operating mode associated with the button. In both example embodiments, electrosurgical energy supplied by the electrosurgical generator 110 may be supplied from the electrosurgical generator 110 to the monopolar electrosurgical electrode 128 via the power cord 122 , the printed circuit board 132 , and the shaft 126 .

[0083] Despite Figure 1The electrosurgical tool 112 includes a user input device 130, but in another example, the user input device 130 may be separate from the electrosurgical tool 112. For example, the user input device 130 may additionally or alternatively include one or more foot pedals that are actuatable to control the operation of the electrosurgical tool 112, as described above. The foot pedal may be communicatively coupled to the electrosurgical generator 110 to provide a signal in response to actuation of the foot pedal.

[0084] In some examples, the electrosurgical tool 112 may also include one or more light sources 140 configured to emit light. In some embodiments, the light source 140 may be positioned at the distal end of the housing 123 and / or the distal end of the shaft 126 to directly provide light in the distal direction and illuminate the surgical distal end of the monopolar electrosurgical electrode 128.

[0085] In other embodiments, Figure 1 As shown, the light source 140 can be optically coupled to an optical structure 142 that is configured to receive light emitted by the light source 140 and transmit the light in a distal direction toward a surgical site to illuminate the surgical site when electrosurgery is performed using the monopolar electrosurgical electrode 128. Although arranging the light source 140 to directly illuminate the surgical area can help, for example, reduce manufacturing costs, using the optical structure 142 to transmit light can help improve the quality of light emitted from the electrosurgical tool 112 (e.g., by providing light in a manner that improves uniformity and / or reduces heat generation).

[0086] As an example, in an embodiment including the optical structure 142, the optical structure 142 may include at least one optical structure selected from the group consisting of an optical lens, a non-fiber optical waveguide, and an optical fiber. When the optical structure 142 includes an optical lens (e.g., a parabolic reflective lens, an aspheric lens, and / or a Fresnel lens), the optical structure 142 may help guide the light emitted by the light source 140 in a distal direction, thereby improving the quality of the light illuminating the surgical site. The optical structure 142 may additionally or alternatively include a non-fiber optical waveguide and / or an optical fiber to transmit light over a relatively long distance in the axis 126. For example, the optical waveguide may transmit light in a distal direction by total internal reflection. In such an embodiment, the optical waveguide may include a cladding and / or an air gap on an outer surface of the optical waveguide to help promote total internal reflection. In some embodiments, the non-fiber optical waveguide may be formed as a single, one-piece, integral structure.

[0087] In some examples, the optical structure 142 may additionally or alternatively include other light shaping optical components, such as multiple facets, one or more prisms, and / or one or more gratings. Although the optical structure 142 may help improve the quality of light directed to the surgical site, in other examples, the electrosurgical tool 112 may omit the optical structure 142 so that light is emitted directly from the light source 140 to the surgical area without transmitting the light through the optical structure 142.

[0088] exist Figure 1 In the embodiment of the present invention, the light source 140 can be coupled to the shaft 126. In this way, the light source 140 can also move telescopically relative to the handle 124 with the shaft 126. However, in other examples, the light source 140 can be located in the internal cavity 252 of the handle 124 and / or coupled to the external surface of the handle 124. As an example, the light source 140 can include one or more light emitting diodes (LEDs), organic light emitting diodes (OLEDs), optical fibers, non-fiber waveguides, and / or lenses. In addition, for example, the light source 140 can include a light emitting diode printed circuit board (LED PCB) having one or more light sources (e.g., LEDs).

[0089] The optical structure 142 can be located at the distal end of the shaft 126. In some examples, the optical structure 142 can circumferentially surround the monopolar electrosurgical electrode 128 to emit light distally around all sides of the monopolar electrosurgical electrode 128. This can help reduce shadows and provide more consistent illumination in all rotational alignments of the shaft 126 relative to the housing 123 and / or the electrosurgical tool 112 relative to the target tissue. However, in other examples, the optical structure 142 can extend partially but not completely around the monopolar electrosurgical electrode 128.

[0090] 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 also supply power from a direct current (DC) power source 144 to the light source 140. In one example, the DC power source 144 may include a battery disposed in the handle 124, a plug of the power cord 122, and / or a battery holder disposed along the power cord 122 between the handle 124 and the plug. Figure 1 The electrosurgical tool 112 includes a DC power source 144, but in other examples, the DC power source 144 may be separate and distinct from the electrosurgical tool 112. For example, in another example, the electrosurgical generator 110 may include a DC power source 144.

[0091] Additionally, in embodiments that include the light source 140, the user input device 130 may be operable to cause the light source 140 to emit light. In one example, the user input device 130 may include a button that independently controls the light source 140, separate from a button that controls an electrosurgical mode of operation of the electrosurgical tool 112. In another example, the user input device 130 and the printed circuit board 132 may be configured such that operation of the button that controls the electrosurgical mode of operation simultaneously controls operation of the light source 140 (e.g., when the button is operated to apply electrosurgical energy at the monopolar electrosurgical electrode 128, the light source 140 may be automatically actuated to emit light).

[0092] like Figure 1 As shown, in response to operation of the user input device 130 to actuate the light source 140, the DC power source 144 can provide power (e.g., a DC voltage) to the light source 140 through the printed circuit board 132, the housing conductor 134, and / or the shaft conductor 136. In this embodiment, one or more of the conductive components of the housing conductor 134 can be configured to supply 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. Therefore, when the shaft 126 and the light source 140 are telescopically moved relative to the handle 124, the housing conductor 134 can additionally or alternatively help provide electrical communication between the DC power source 144 and the light source 140.

[0093] Although in the above example, the user input device 130 on the handle 124 can be operated to control the operation of the light source 140, the light source 140 can be operated additionally or alternatively via one or more user input devices on the electrosurgical generator 110 (e.g., via the user interface 116) and / or via one or more user input devices on the plug of the power cord 122.

[0094] In an example, the electrosurgical tool 112 may additionally or alternatively include features for exhausting surgical smoke from the target tissue to a location outside the surgical site. Surgical smoke is a byproduct of various surgical procedures. For example, during a surgical procedure, surgical smoke may be produced as a byproduct of an electrosurgical unit (ESU), a laser, an electrocautery device, an ultrasonic device, and / or other electric surgical instruments (e.g., a bone saw and / or a drill). In some cases, surgical smoke may contain toxic gases and / or biological products produced by tissue destruction. In addition, surgical smoke may contain an unpleasant odor. For these and other reasons, many operating guidelines indicate that surgical personnel should be exposed to surgical smoke or minimized.

[0095] In order to reduce (or minimize) exposure to surgical smoke, a smoke exhaust system may be used during surgical procedures. Generally, the smoke exhaust system may include a suction pump 146 that can generate sufficient suction and / or vacuum pressure to draw surgical smoke away from the surgical site. In some embodiments, the smoke exhaust system may be connected to an exhaust system (e.g., an in-wall exhaust system) that exhausts surgical smoke from the operating room. In other embodiments, the smoke exhaust system may filter air containing surgical smoke and return the air to the operating room. In an example, the suction pump 146 and the electrosurgical generator 110 may be provided as separate devices or integrated in a single device (e.g., in a common housing).

[0096] like Figure 1 As shown, the shaft 126 may include a smoke exhaust channel 148 located in the inner hole 254 of the shaft 126. The smoke exhaust channel 148 may also include a smoke inlet that extends circumferentially around the central axis of the distal portion of the monopolar electrosurgical electrode 128. In this arrangement, the smoke inlet of the smoke exhaust channel may help to receive surgical smoke into the smoke exhaust channel 148 in all rotational alignment orientations of the monopolar electrosurgical electrode 128 relative to the handle 124 and / or the electrosurgical tool 112 relative to the target tissue. However, in another example, the smoke exhaust channel 148 may include one or more smoke inlets that do not extend circumferentially around the monopolar electrosurgical electrode 128.

[0097] In one example, the smoke exhaust passage 148 can include an outer tube separated from the optical structure 142 by an air gap. For example, the shaft 126 can include a plurality of brackets extending between the optical structure 142 and the outer tube of the smoke exhaust passage 148 to provide an air gap between the outer tube and the optical structure 142. In one embodiment, the optical structure 142 can include brackets such that the optical structure 142 and the brackets are formed as a single, one-piece, unitary structure. In another embodiment, the brackets can be formed as a single, one-piece, unitary structure with the outer tube of the smoke exhaust passage 148. In another embodiment, the brackets can be separate from the outer tube of the smoke exhaust passage 148 and the optical structure 142.

[0098] In one example, the smoke exhaust passage 148 of the shaft 126 defines a first portion of the smoke flow path, and the internal cavity 252 of the handle 124 defines a second portion of the smoke flow path. Figure 2A partial cross-sectional view of an electrosurgical tool 112 according to an embodiment of the present example is shown. In this arrangement, surgical smoke can be received from the surgical site into the smoke exhaust passage 148 provided by the internal hole 254 of the shaft 126 and flow proximally along the smoke exhaust passage 148 into the internal cavity 252 of the handle 124. In the internal cavity 252 of the handle 124, the smoke can further flow to the smoke tube 150, which is coupled to the proximal end of the handle 124 and is configured to transport the smoke from the handle 124 to the suction pump 146.

[0099] As described above, the monopolar electrosurgical electrode 128 can apply electrosurgical energy to the target tissue to perform an electrosurgical operation (e.g., cutting, coagulating, ablating, and / or sealing the target tissue). In an example, the monopolar electrosurgical electrode 128 includes an electrosurgical substrate formed of a conductive material. As an example, the conductive material can be stainless steel.

[0100] As described in further detail below, the electrosurgical substrate can extend in an axial direction from a proximal end of the monopolar electrosurgical electrode 128 to a distal end of the monopolar electrosurgical electrode 128. The proximal end of the monopolar electrosurgical electrode 128 can receive electrosurgical energy from the electrosurgical tool 112 (e.g., via the shell conductor 134 and the shaft conductor 136 as described above), and the distal working portion of the monopolar electrosurgical electrode 128 can apply the electrosurgical energy to the target tissue. In one embodiment, the electrosurgical substrate can include a shaft portion extending from the proximal end of the monopolar electrosurgical electrode 128 to the distal working portion of the monopolar electrosurgical electrode 128. The distal working portion can be configured to perform at least one of cutting or coagulating tissue via the electrosurgical energy received from the electrosurgical tool 112.

[0101] In some examples, the distal working portion can define an electrosurgical blade. For example, the electrosurgical blade can include (i) a first lateral surface, (ii) a second lateral surface opposite the first lateral surface, (iii) a first major surface extending between the first lateral surface and the second lateral surface on a first side of the electrosurgical blade, and (iv) a second major surface extending between the first lateral surface and the second lateral surface on a second side of the electrosurgical blade opposite the first side. The first lateral surface and the second lateral surface have a relatively small surface area compared to the surface area of ​​the first major surface and the second major surface, so that the thickness of the electrosurgical blade (e.g., the dimension between the first major surface and the second major surface) is relatively small compared to the length (e.g., the dimension extending between the proximal end and the distal end of the monopolar electrosurgical electrode 128) and the width (e.g., the dimension between the first lateral surface and the second lateral surface).

[0102] Reference now Figure 3-13 , shows an embodiment of an electrosurgical tool 112 according to an example. Figure 3Depicted is a perspective view of an electrosurgical tool 112 according to an example. Figure 4 Depicted is a cross-sectional view of the electrosurgical tool 112 taken along a longitudinal axis 350 of the electrosurgical tool, according to an example.

[0103] like Figure 3-4 As shown, the electrosurgical tool 112 includes a handle 124 defining an internal cavity 252, and a shaft 126 extending distally from the internal cavity 252 of the handle 124. As described above, the shaft 126 defines an internal hole 254. The shaft 126 has a longitudinal axis 350 extending between the proximal end 126A of the shaft 126 and the distal end 126B of the shaft 126. In addition, the monopolar electrosurgical electrode 128 extends distally from the distal end 126B of the shaft 126. In this embodiment, the monopolar electrosurgical electrode 128 is directly coupled to or integrally formed with the shaft 126. However, in another embodiment, the monopolar electrosurgical electrode 128 can be indirectly coupled to the shaft 126 through an intermediate conductor, so that the monopolar electrosurgical electrode 128 receives electrosurgical energy conducted through the printed circuit board 132, the shaft 126, and the intermediate conductor.

[0104] exist Figure 3-13 In the example shown, the shaft 126 can be telescopically moved within the internal cavity 252 of the handle 124 to adjust the distance of the distal end of the monopolar electrosurgical electrode 128 relative to the handle 124. As described above, telescopically moving the shaft 126 relative to the handle 124 can facilitate adjusting the length of the electrosurgical tool 112 to treat target tissues of different sizes and / or shapes. However, as described above, in other examples, the shaft 126 can be axially fixed to the handle 124 (e.g., fixedly coupled to the handle 124) so ​​that the shaft 126 cannot move axially relative to the handle 124.

[0105] Additionally, in this example, the shaft 126 is rotatable relative to the handle 124. Since the monopolar electrosurgical electrode 128 is fixedly coupled to the shaft 126 in this example, rotating the shaft 126 causes the monopolar electrosurgical electrode 128 to correspondingly rotate relative to the handle 124. As described above, rotating the monopolar electrosurgical electrode 128 relative to the handle 124 can facilitate adjusting the angle of the monopolar electrosurgical electrode 128 relative to one or more user input devices 130 of the electrosurgical tool 112. However, as described above, in other examples, the shaft 126 can be rotationally fixed relative to the handle 124 such that the shaft 126 cannot rotate relative to the handle 124.

[0106] In some examples, the electrosurgical tool 112 can include a collar 356 located at the distal end of the handle 124. The collar 356 can be rotated relative to the handle 124 to increase and / or decrease friction between the outer surface of the shaft 126 and the inner surface of the collar 356. In this manner, the collar 356 allows and / or prevents (i) axial movement of the shaft 126 relative to the handle 124, and / or (ii) rotation of the shaft 126 and the monopolar electrosurgical electrode 128 relative to the handle 124.

[0107] As described above, in some examples, the shaft 126 may be rotatable relative to the handle 124, but one or more components within the interior bore 254 of the shaft 126 remain rotationally fixed relative to the handle 124. For example, as described in further detail below, the electrosurgical tool 112 may also include a smoke exhaust passage 148, a light source 140, and an optical structure 142, which may be rotationally fixed relative to the handle 124. Allowing the monopolar electrosurgical electrode 128 to rotate with the shaft 126 while rotationally fixing the smoke exhaust passage 148, the light source 140, and / or the optical structure 142 may help simplify the design and / or reduce the manufacturing cost of the electrosurgical tool 112.

[0108] In some examples, the rotational arrangement orientation of the components of the electrosurgical tool 112 can be achieved at least in part by extending the monopolar electrosurgical electrode 128 distally from the distal end 126B of the shaft 126 such that (i) the shaft 126 conducts electrosurgical energy to the monopolar electrosurgical electrode 128, and (ii) rotation of the shaft 126 relative to the handle 124 causes the monopolar electrosurgical electrode 128 to rotate accordingly relative to the handle 124. For example, at least a portion of the shaft 126 can be formed of a conductive material such that the shaft 126 can supply electrosurgical energy to the monopolar electrosurgical electrode 128.

[0109] In one example, the monopolar electrosurgical electrode 128 and the shaft 126 are formed as a one-piece, unitary structure. This is beneficial in embodiments where the monopolar electrosurgical electrode 128 is permanently fixed to the shaft 126 so that the monopolar electrosurgical electrode 128 cannot be replaced with another monopolar electrosurgical electrode 128. In another example, the monopolar electrosurgical electrode 128 and the shaft 126 can be separate components that are coupled to each other (e.g., by welding, brazing, and / or friction fit coupling). In some embodiments where the monopolar electrosurgical electrode 128 and the shaft 126 are separate components, the monopolar electrosurgical electrode 128 can be detachable from the shaft 126 and can be replaced with another monopolar electrosurgical electrode 128. In other embodiments, the monopolar electrosurgical electrode 128 can be permanently fixed to the shaft 126 so that the monopolar electrosurgical electrode 128 cannot be replaced with another monopolar electrosurgical electrode 128.

[0110] exist Figure 3-41 , the shaft 126 includes a conductive portion 126C and an insulator portion 126D. As described above, the monopolar electrosurgical electrode 128 may extend from the conductive portion 126C of the shaft 126. The insulator portion 126D of the shaft 126 may be a sleeve structure covering the interface between the monopolar electrosurgical electrode 128 and the conductive portion 126C of the shaft 126. In this arrangement, the insulator portion 126D may help mitigate arcing and / or help supply electrosurgical energy to the monopolar electrosurgical electrode 128. In addition, the shaft 126 may include a layer of insulator material 126E (e.g., a heat shrink material) that covers the remaining portion of the conductive portion 126C of the shaft 126 (e.g., the portion not covered by the insulator portion 126D of the shaft 126) to mitigate arcing and / or help supply electrosurgical energy to the monopolar electrosurgical electrode 128.

[0111] As described above, the printed circuit board 132 is electrically coupled to the shaft 126 to provide at least a portion of the circuitry for supplying electrosurgical energy from the power cord 122 to the monopolar electrosurgical electrode 128. Figure 4 As shown, the printed circuit board 132 includes a first end 132A located in the internal cavity 252 of the handle 124, a second end 132B located in the internal hole 254 of the shaft 126, and a transmission portion extending between the first end 132A and the second end 132B of the printed circuit board 132.

[0112] The first end 132A may be fixedly coupled to the handle 124 such that the first end 132A of the printed circuit board 132 does not move axially and / or rotationally relative to the handle 124. Figure 4 In the embodiment, the proximal section of the printed circuit board 132 (eg, the portion of the printed circuit board 132 that is closer to the first end 132A than to the second end 132B) includes a switch 138 (eg, Figure 1 ) and is fixedly coupled to the handle 124 adjacent to the user input device 130. Figure 7A-7B The example shown in FIG. 1 further details the proximal section of the printed circuit board 132 .

[0113] The second end 132B of the printed circuit board 132 may be fixedly coupled to at least one component within the internal bore 254 of the shaft 126. Figure 3 4, the second end 132B of the printed circuit board 132 includes an LED PCB that is fixedly coupled to the heat sink 458. This allows the printed circuit board 132 to also supply power from the DC power source 144 to the light source 140. In this example, the light source 140 is configured to move axially with the shaft 126 relative to the handle 124, but remain rotationally fixed relative to the handle 124 while the shaft 126 is rotatable relative to the handle 124.

[0114] In this arrangement, when the shaft 126 is in a distal (e.g., fully extended) position relative to the handle 124, the length of the transmission portion of the printed circuit board 132 can be equal to or greater than the distance between the first end 132A and the second end 132B of the printed circuit board 132. When the shaft 126 is in a position proximal to the distal position relative to the handle, slack in the transmission portion can accumulate in the internal bore 254 of the shaft 126 and / or the internal cavity 252 of the handle 124. For example, the printed circuit board 132 can be a flexible printed circuit board so that when the shaft 126 moves proximally and / or distally relative to the handle 124, the transmission portion can deform, bend, and / or fold upon itself to occupy the open space in the internal bore 254 of the shaft 126 and / or the internal cavity 252 of the handle 124. Additionally, for example, the transmission portion can twist and / or spirally deform in the open space in response to rotation of the shaft 126 relative to the handle 124.

[0115] As described above, the electrosurgical tool 112 includes one or more components that can help maintain an electrical connection between the printed circuit board 132 and the interior surface of the shaft 126 (and, therefore, the monopolar electrosurgical electrode 128). Figure 3-4 14, a distal section of the printed circuit board 132 (e.g., a section of the transmission portion that is located in the internal bore 254 and distal to the proximal section of the printed circuit board 132) is at least partially in electrical communication with the interior surface of the shaft 126 via a heat sink 458 in the internal bore 254 of the shaft 126. In addition to helping transfer heat away from the light source 140, the heat sink 458 can also provide an anchor point that can electrically couple the printed circuit board 132 to the shaft 126 in conjunction with one or more other components. Figure 5-6 1 shows an embodiment in which the heat sink 458 helps electrically couple the printed circuit board 132 to the interior surface of the shaft 126 according to some examples. However, in other examples, Figure 5-6 The concepts shown and described may be expanded to apply to embodiments that omit the heat sink 458 and include a different anchor structure in the internal bore 254 of the shaft 256 .

[0116] Figure 5 Depicts a method according to an example Figure 3 A partial cross-sectional view of axis 126 along line 360 ​​in FIG. Figure 5 , shaft 126 includes an inner surface 526A and an outer surface 526B. At least inner surface 526A is formed of one or more conductive materials. In some examples, outer surface 526B and / or a wall of shaft 126 extending between inner surface 526A and outer surface 526B may also be formed of the one or more conductive materials.

[0117] like Figure 5As shown, the heat sink 458 is located in the internal hole 254 of the shaft 126, and the printed circuit board 132 is located between the heat sink 458 and the shaft 126. Figure 5 As shown, the electrosurgical tool 12 includes a brush 562 that electrically couples the printed circuit board 132 to the interior surface 526A of the shaft 126. For example, the brush 562 may be located between the printed circuit board 132 and the interior surface 526A of the shaft 126, and the brush 562 may include a conductive material (e.g., a metal such as copper) such that the brush 562 electrically couples the conductive contact 564 of the printed circuit board 132 to the interior surface 526A of the shaft 126.

[0118] The heat sink 458, the printed circuit board 132, the brush 562, and the interior surface 526A of the shaft 126 can have respective sizes and shapes such that the printed circuit board 132 can be electrically connected to the interior surface 526A through the brush 562 in all axial positions and / or rotational orientations of the shaft 126 relative to the handle 124. For example, the brush 562 and the heat sink 458 can have respective sizes and shapes such that the printed circuit board 132 is urged toward the heat sink 458 by the brush 562 to maintain the electrical connection between the conductive contacts 564 of the printed circuit board 132 and the brush 562. For example, the heat sink 458, the printed circuit board 132, and the brush 562 can be configured such that the brush 562 clamps the printed circuit board 132 to the heat sink 458. Figure 5 In one embodiment, the brushes 562 may extend along at least half of the circumference of the heat sink 458 to help maintain the brushes 562 in electrical communication with the conductive contacts 564 of the printed circuit board 132 .

[0119] In addition, if Figure 5 As shown, the electrosurgical tool 112 may also include an attachment member 566 that couples the brush 562, the printed circuit board 132, and the heat sink 458 to each other. For example, the attachment member 566 may extend around the brush 562, the printed circuit board 132, and the heat sink 458 and apply a radially inward force to them. This may help improve the contact between the conductive contacts 564 of the printed circuit board 132 and the brush 562, and / or help fix the position of the brush 562 relative to the heat sink 458 and the printed circuit board 132.

[0120] In one example, the attachment member 566 can be a band formed of a heat shrink material. In this example, the process of forming the electrosurgical tool 112 can include (i) positioning the attachment member 566 around the assembly of the heat sink 458, the printed circuit board 132, and the brush 562, and (ii) applying heat to the attachment member 566 to shrink the attachment member 566 on the assembly and apply a radially inward force to the assembly. As other examples, the attachment member 566 can include at least one component selected from the group consisting of Kapton tape, an O-ring, and an adhesive. In addition, in other exemplary embodiments, the attachment member 566 can be omitted.

[0121] In some examples, the heat sink 458 may include a groove 568 extending along at least a portion of the perimeter of the heat sink 458, and at least a portion of the printed circuit board 132 may be located in the groove 568 of the heat sink 458. Figure 5 4, the conductive contacts 564 are located in recesses 568 of the heat sink 458. The recesses 568 can help mitigate axial movement of the brush 562 relative to the printed circuit board 132, the heat sink 458, and / or the shaft 126. Additionally, the recesses 568 can help provide additional space for the brush 562 within the internal bore 254 of the shaft 126.

[0122] To electrically couple the printed circuit board 132 to the shaft 126, (i) at least a portion of the brush 562 is in electrical communication with the conductive contact 564 of the printed circuit board 132, and (ii) at least a portion of the brush 562 is in electrical communication with the interior surface 526A of the shaft 126. Figure 5 , the brush 562 includes a distal end 570, a proximal end 572, and a center portion 574 between the distal end 570 and the proximal end 572. The center portion 574 can engage the conductive contact 564, and the distal end 570 and the proximal end 572 can engage the inner surface 526A of the shaft 126.

[0123] In some examples, the center portion 574 can have a shape that corresponds to the shape of the conductive contact 564 of the printed circuit board 132 (e.g., in the groove 568 of the heat sink 458). In one example, at least a portion of the groove 568 can define a substantially flat surface for engaging the printed circuit board 132. The conductive contact 564 and the portion of the brush 562 that engages the conductive contact 564 can also have a substantially flat surface. This helps provide relatively consistent contact between the conductive contact 564 and the brush 562. However, in other examples, the portion of the groove 568 that engages the printed circuit board 132 at the conductive contact 564, the conductive contact 564, and / or the brush 562 can have a different shape (e.g., a curved shape).

[0124] like Figure 5As shown, in some examples, the distal end 570 of the brush 562 and the proximal end 572 of the brush 562 can extend radially outward from the central portion 574 to directly contact the inner surface 526A of the shaft 126. The distal end 570 can also extend distally from the central portion 574, and the proximal end 572 can extend proximally from the central portion 574. In this arrangement, the brush 562 can have appropriate flexibility to accommodate the forces applied to the brush 562 by (i) the shaft 126 on one side and (ii) the heat sink 458 and the printed circuit board 132 on the other side. Additionally or alternatively, this arrangement can help reduce friction when the shaft 126 rotates relative to the brush 562.

[0125] In an example, the brush 562 may extend along at least a portion of the circumference of the inner surface 562A of the shaft 126 (eg, at a position perpendicular to the axis of the shaft 126). Figure 3 126). For example, the brush 562 may extend along at least half of the circumference of the interior surface 526A of the shaft 126 and / or along the entire circumference of the interior surface 526 of the shaft 126. Advantageously, this may allow the brush 562 to electrically couple the conductive contacts 564 of the printed circuit board 132 to the shaft 126 at one or more locations along the circumference of the interior surface 526A of the shaft 126.

[0126] In some examples, at least a portion of the distal end 570 and at least a portion of the proximal end 572 of the brush 562 can have a shape that matches the shape of the inner surface 562A of the shaft 126 (e.g., at least a portion of the distal end 570 and / or the proximal end 572 can have a curved shape that matches the curved profile of the inner surface 526A). This helps to improve the degree of contact between the brush 562 and the shaft 126. In other examples, the distal end 570 and / or the proximal end 572 can have a shape that is different from the shape of the inner surface 526A, as long as the brush 562 is in electrical communication with the inner surface 526A of the shaft 126 at one or more locations on the inner surface 526A.

[0127] As described above, the distal end 570 and / or the proximal end 572 of the brush 562 may define an outer surface of the brush 562 for engaging the inner surface 526A of the shaft 126, and the central portion 574 of the brush 562 may define an inner surface of the brush 562 for engaging the conductive contacts 564 of the printed circuit board 132. However, in other examples, the brush 562 may be configured differently. For example, in one other example, (i) at least one of the distal end 570, the proximal end 572, and the central portion 574 may define an outer surface of the brush 562, and (ii) at least another of the distal end 570, the proximal end 572, and the central portion 574 may define an inner surface of the brush 562.

[0128] Reference now Figure 6In another example embodiment, the heat sink 458 helps electrically couple the printed circuit board 132 to the interior surface of the shaft 126. According to another example, Figure 6 It also depicts the Figure 3 A partial cross-sectional view of axis 126 along line 360 ​​in FIG. Figure 6 , shaft 126 includes an inner surface 626A and an outer surface 626B. At least inner surface 626A is formed of one or more conductive materials. In some examples, outer surface 626B and / or a wall of shaft 126 extending between inner surface 626A and outer surface 626B may also be formed of the one or more conductive materials.

[0129] exist Figure 6 In the embodiment of the present invention, the electrosurgical tool 112 includes a biasing member 676 that applies a force to the printed circuit board 132 to press the conductive contacts 564 of the printed circuit board 132 into electrical contact with the interior surface 626A of the shaft 126. For example, in Figure 6 , the biasing member 676 is located between the heat sink 458 and the printed circuit board 132, so that a first portion of the biasing member 676 can contact the printed circuit board 132, and a second portion of the biasing member 676 can contact the heat sink 458 to press the conductive contact 564 of the printed circuit board 132 in a radially outward direction toward the inner surface 526A of the shaft 126.

[0130] In an example, the biasing member 676 can have a size and / or shape relative to the corresponding size and / or shape of the heat sink 458, the printed circuit board 132, and the shaft 126 such that when the shaft 126 is rotated relative to the handle 124 and / or the printed circuit board 132, the biasing member 676 presses the conductive contact 564 against the interior surface 626A of the shaft 126 with sufficient force to maintain electrical connectivity.

[0131] In some examples, the biasing member 676 can include an elastic material. This can allow the biasing member 676 to compress and / or expand to facilitate assembly while maintaining contact within the tolerance range of the shaft 126. Additionally or alternatively, forming the biasing member 676 from an elastic material can help prevent fluid from entering. In one example, the biasing member 676 can include an O-ring.

[0132] In some examples, the biasing member 676 can extend along the circumference of the heat sink 458 and provide a gasket that prevents fluid from entering the space between the interior surface 626A of the shaft 126 and the heat sink 458. For example, at an axial position of the biasing member 676 along the longitudinal axis 350, the space between the interior surface 626A of the shaft 126 and the heat sink 458 may be substantially (i) occupied by the combination of the printed circuit board 132 and the biasing member 676 along a first circumferential portion of the space and (ii) occupied by the biasing member 676 along a second circumferential portion of the space. In examples where the biasing member 676 provides a gasket, the biasing member 676 can prevent foreign matter (e.g., fluid and / or debris) from moving proximally along the shaft 126 and into the interior cavity 252 of the handle 124 (e.g., outside of the smoke exhaust passage 148 and the smoke exhaust chamber 152 (if included)). This can help reduce such foreign debris from contacting electrical components within the handle 124 (e.g., a proximal portion of the printed circuit board 132).

[0133] In some examples, the heat sink 458 can include a groove 668 extending along at least a portion of the perimeter of the heat sink 458, and the biasing member 676 can be positioned in the groove 668. The groove 668 can help maintain the biasing member 676 in a fixed axial position (e.g., along the longitudinal axis 350) relative to the heat sink 458. As such, the groove 668 can help mitigate axial movement of the biasing member 676 relative to the printed circuit board 132, the heat sink 458, and / or the shaft 126. Additionally, the groove 668 can help provide additional space for the biasing member 676 within the inner bore 254 of the shaft 126.

[0134] In some examples, the groove 668 may also extend along the entire circumference of the heat sink 458. For example, in examples where the biasing member 676 extends along the entire circumference of the heat sink 458, the groove 668 may extend along the entire circumference of the heat sink 458 to help maintain the biasing member 676 in a fixed axial position. However, in other examples, the groove 668 may extend less than the entire circumference of the heat sink 458. For example, this may help reduce costs by improving assembly processes and / or reducing machining costs.

[0135] Reference now Figure 7A-7B , shows an embodiment of a printed circuit board 132 according to an example. Specifically, Fig. 7A A first side view of the printed circuit board 132 is shown, and Figure 7B Shown with Fig. 7A A second side view of the printed circuit board 132 is shown opposite the first side view.

[0136] exist Figure 7A-7BIn the embodiment, the printed circuit board 132 is a flexible printed circuit board. For example, the printed circuit board 132 can include a plurality of electrical circuits located on a flexible substrate. In one embodiment, for example, the printed circuit board 132 can include one or more conductive trace layers of a conductive material (e.g., copper) located on a polyimide dielectric layer.

[0137] like Figure 7A-7B As shown, the printed circuit board 132 has a first end 132A, a second end 132B, and a transmission portion 777 extending between the first end 132A and the second end 132B. As described above, the first end 132A can be fixedly coupled to the handle 124 in the internal cavity 252 of the handle 124 so that the first end 132A of the printed circuit board 132 does not move axially and / or rotationally relative to the handle 124. For example, in Fig. 7A , the proximal section 732A of the printed circuit board 132 includes the switch 138 and is fixedly coupled to the handle 124 adjacent to the user input device 130. The switch 138 can be connected to the user input device 130 (e.g., Figure 3 Multiple buttons 330A, 330B) shown in FIG. 1 are actuated to control the electrosurgical energy supplied to the monopolar electrosurgical electrode 128.

[0138] like Figure 7B As shown, the printed circuit board 132 may include a first PCB reinforcement 778, which is coupled to the proximal section 732A on the second side of the printed circuit board 132 to assist in fixedly coupling the proximal section 732A to the handle 124. The first PCB reinforcement 778 can be formed of any material suitable for increasing the stability and / or rigidity of the proximal section 732A of the printed circuit board 132. As an example, the first PCB reinforcement 778 can include a thermally conductive material, such as aluminum. This can also help transfer heat away from the proximal section 732A of the printed circuit board 132.

[0139] The proximal section 732A of the printed circuit board 132 may also include a plurality of power line contacts 780 for electrically connecting to the power line 122 (eg, Figure 1 The corresponding conductors are shown in Fig. 7A , the printed circuit board 132 includes three power line contacts 780 configured to couple to the three conductors of the power line 122 for supplying electrosurgical energy from the electrosurgical generator 110 to the printed circuit board 132. In examples where the DC power source 144 is located along the power line 122 and / or at a plug of the power line 122, the printed circuit board 132 may include two power line contacts 780 configured to couple to the two conductors of the power line 122 to provide DC power from the DC power source 144 to the light source 140.

[0140] As described above, the second end 132B of the printed circuit board 132 may be fixedly coupled to at least one component (eg, the heat sink 458) within the internal bore 254 of the shaft 126. Figure 3-4 In the example shown in FIGS. 7A-7B , the second end 132B of the printed circuit board 132 includes the light source 140 and is fixedly coupled between the heat sink 458 and the optical structure 142. Figure 7B As shown, the printed circuit board 132 may include a second PCB reinforcement 782 that is coupled to the second end 132B on the second side of the printed circuit board 132 to assist in fixedly coupling the second end 132B between the heat sink 458 and the optical structure 142. The second PCB reinforcement 782 can be formed of any material suitable for increasing the stability and / or rigidity of the second end 132B and / or the light source 140. As an example, the second PCB reinforcement 782 can include a thermally conductive material, such as aluminum. This can also help transfer heat away from the light source 140 and toward the heat sink 548. The coupling of the second end 132B to the heat sink 548 and / or the optical structure 142 will be described below with reference to Figure 12-13 A further detailed description is given.

[0141] The transmission portion 777 extends between the first end 132A and the second end 132B. Figure 4 and Figure 7A-7B As shown, the printed circuit board 132 is elongated in an axial dimension extending between the first end 132A and the second end 132B, and the axial dimension may be parallel to the longitudinal axis 350 of the shaft 126 (eg, Figure 3 ). In this arrangement, when the shaft 126 is in a distal (e.g., fully extended) position relative to the handle 124, the length of the transmission portion 777 of the printed circuit board 132 can be equal to or greater than the distance between the first end 132A and the second end 132B of the printed circuit board 132. When the shaft 126 is in a position proximal to the distal position relative to the handle, slack in the transmission portion can accumulate in the internal bore 254 of the shaft 126 and / or the internal cavity 252 of the handle 124.

[0142] For example, in Figure 4-6 In the embodiment shown in FIG. 2 , the heat sink 458 does not extend to the proximal end of the internal bore 254, so that a space is provided in the internal bore 254 between the heat sink 458 and the proximal end of the shaft 126. In this way, the space can accommodate slack in the printed circuit board 132, thereby facilitating axial movement of the shaft 126 and the second end 132B of the printed circuit board 132 relative to the first end 132A of the printed circuit board 132.

[0143] like Fig. 7AAs shown, the printed circuit board 132 includes a conductive contact 564 for electrically coupling the printed circuit board 132 to the interior surface 526A, 626A of the shaft 126, and the conductive contact 564 is located between the first end 132A and the second end 132B of the printed circuit board 132. The conductive contact 564 can include a portion of the conductive trace of the printed circuit board 132 that is exposed and not covered by the dielectric material. Therefore, the exposed conductive material of the conductive contact 564 can be electrically coupled to the interior surface 526A, 626A of the shaft 126, as described above. As an example, the conductive contact 564 can include copper.

[0144] like Fig. 7A As shown, the width W1 of the printed circuit board 132 at the conductive contact 564 can be greater than the width W2 of the printed circuit board 132 at the first section of the printed circuit board 132 proximal to the conductive contact 564 and / or at the second section of the printed circuit board 132 distal to the conductive contact 564. In this arrangement, the conductive contact 564 can be enlarged relative to one or more sections of the transmission portion 777 to increase the surface area of ​​electrical contact with the interior surface 526A, 626A of the shaft 126, while the proximal and / or distal sections of the transmission portion 777 can have relatively smaller dimensions to address space limitation considerations caused by slack accumulation in the transmission portion 777 at one or more axial positions of the shaft 126 relative to the handle 124.

[0145] In this arrangement, the first end 132A of the printed circuit board 132 can be connected to the power line 122 (eg, Figure 1 The transmission portion 777 can supply the electrosurgical energy from the first end 132A to the conductive contacts 564, which can supply the electrosurgical energy to the interior surfaces 526A, 626A of the shaft 126, which can supply the electrosurgical energy to the monopolar electrosurgical electrode 128. In examples, the printed circuit board 132 can supply electrosurgical energy in this manner in all axial positions and / or all rotational orientations of the shaft 126 relative to the handle 124. Additionally, in examples including the light source 140, the first end 132A of the printed circuit board 132 can be connected to the power cord 122 (such as Figure 1 As shown) receives DC power, and the transmission portion 777 can supply DC power from the first end 132A to the light source 140 at the second end 132B.

[0146] As described above, the printed circuit board 132 may include a first PCB reinforcement 778 located at the proximal section 732A and / or a second PCB reinforcement 782 located at the second end 132B of the printed circuit board. In an example, the PCB reinforcement may be omitted from at least a portion or all of the transmission portion 777 of the printed circuit board. This may allow the transmission portion 777 to have greater flexibility than the second end 132B and / or the proximal section 732A, which in turn may allow the transmission portion 777 to deform and / or bend when accommodating the movement of the shaft 126 relative to the handle 124.

[0147] Figure 8 Another embodiment of a printed circuit board 132 according to another example is depicted. Specifically, Figure 8 The distal section of the printed circuit board 132, the second end 132B, the light source 140, and the conductive contacts 564 are depicted according to this example. Figure 8 As shown, the transmission portion 777 can have a rectangular shape and the conductive contact 564 can have a triangular shape. The triangular shape of the conductive contact 564 can help increase the surface area of ​​the electrical contact.

[0148] Reference now Fig. 9 , shows an enlarged view of a cross section of the distal end 126B of the shaft 126 and the monopolar electrosurgical electrode 128 taken through the longitudinal axis 350 according to an example. Fig. 9 As shown, the distal portion 128A of the monopolar electrosurgical electrode 128 can define a working end configured to apply electrosurgical energy to tissue. The proximal portion 128B of the monopolar electrosurgical electrode 128 can include a first leg 984A extending from the distal end 126B of the shaft 126, and a second leg 984B extending from the distal end of the conductive portion 126C of the shaft 126.

[0149] exist Fig. 9 126, the first leg 984A and the second leg 984B are diametrically opposed to each other along the circumference of the distal end 126B of the shaft 126. In addition, the proximal surface 985 of the proximal portion 128B of the monopolar electrosurgical electrode 128 can extend in a distal direction toward the central axis of the shaft 126 to define a gap 986 between the proximal surface 985 and a flat surface 987 at the distal-most end of the shaft 126. The gap 986 can help improve air flow and suction at the distal end 126B of the shaft 126.

[0150] In addition, if Fig. 9 As shown, the sleeve structure of the insulator portion 126D can extend around the optical structure 142. The sleeve structure can be an optically opaque material. In order to enhance the intensity of light emitted from the optical structure 142, at least a portion of each distal transmission surface of the optical structure 142 can extend to a position distal to the distal end of the sleeve structure of the insulator portion 126D.

[0151] As described above, the monopolar electrosurgical electrode 128 may include a proximal portion 128B extending from the distal end of the shaft 126, and a distal portion 128A including a working end configured to apply electrosurgical energy to tissue. Figure 3-4 and Fig. 9 1, the central axis of the distal portion 128A of the monopolar electrosurgical electrode 128 and the central axis of the smoke exhaust passage 148 are collinear. In this arrangement, the smoke exhaust passage 148 can have a substantially constant size along the circumference of the monopolar electrosurgical electrode 128. This can help provide relatively consistent suction to each point around the monopolar electrosurgical electrode 128. However, in other examples, the central axes of the monopolar electrosurgical electrode 128 and the shaft 126 can be offset and parallel relative to each other.

[0152] In addition, if Figure 3-4 As shown in FIGS. 9 and 10 , the smoke exhaust channel 148 may define a space without any other structure between the proximal end 148A of the smoke exhaust channel 148 and the distal end 148B of the smoke exhaust channel 148. Compared with other embodiments in which the monopolar electrosurgical electrode 128 and / or other components are arranged in the smoke exhaust channel 148, this can more effectively utilize the relatively limited size of the internal hole 254 to enhance the suction through the smoke exhaust channel 148.

[0153] Additionally, as described above, according to some examples, the smoke exhaust passage 148 may be rotationally fixed relative to the handle 124 such that the shaft 126 and the monopolar electrosurgical electrode 128 are rotatable relative to the smoke exhaust passage 148 . Figure 10-11 The smoke exhaust passage 148 and the shaft 126 are depicted according to an example. Figure 4 and 10 -11, at least a portion of the smoke exhaust passage 148 may have a non-circular shape to prevent the smoke exhaust passage 148 from rotating relative to the handle 124 when the shaft 126 and the monopolar electrosurgical electrode 128 rotate relative to the handle 124.

[0154] For example, the proximal end 148A of the smoke exhaust passage 148 may include a non-rotating fitting configured to engage with a correspondingly shaped structure in the handle 124, and the non-rotating fitting may have a non-circular cross-sectional shape. Figure 4 and 10 In the embodiment, the proximal end 148A of the smoke exhaust passage 148 has a hexagonal feature that engages with a hexagonal socket formed on the inner surface of the handle 124 to prevent rotation between the smoke exhaust passage 148 and the handle 124. Fig.11 As shown, a gap may be defined between the shaft 126 and the smoke exhaust passage 148 to provide for rotation of the shaft 126 relative to the smoke exhaust passage 148 .

[0155] like Fig.10 As shown, the non-rotating fitting at the proximal end 148A of the smoke exhaust passage 148 may include a through hole 1088 having a cross-sectional area that is smaller than the cross-sectional area of ​​the body 148C of the smoke exhaust passage 148 located proximal to the non-rotating fitting. When smoke leaves the proximal end 148A of the smoke exhaust passage 148, the relatively small size of the through hole 1088 may help direct the smoke into a relatively small volume of space. This may beneficially help reduce or prevent exposure of electrical components in the internal hole 125 of the handle 124 to the smoke.

[0156] Fig.12 A partially exploded view of the components of the printed circuit board 132, the light source 140, the optical structure 142, the heat sink 458, and the smoke exhaust channel 148 according to an example is shown. Figure 4 , 9 As shown in FIG. 12 , the electrosurgical tool 112 may include a light source 140 and an optical structure 142 located in the shaft 126 of the housing 123. As described above, the light source 140 is configured to emit light into the optical structure 142, and the optical structure 142 is configured to transmit the light from the light source 140 in the distal direction and emit light from the distal end 126B of the shaft 126.

[0157] exist Fig.12 , the light source 140 is located on the second end 132B of the printed circuit board 132. The transmission portion 777 can extend along the smoke exhaust channel 148 and the heat sink 458. In one example, the second end 132B of the printed circuit board 132 can be fixedly connected by a washer (e.g., a star-shaped washer) that is pressed against the proximal end of the heat sink 458 to force the heat sink 458, the second end 132B (e.g., including the second PCB reinforcement 782 and the light source 140) and the optical structure 142 to cooperate with the first leg 984A and / or the second leg 984B of the monopolar electrosurgical electrode 128. For example, Fig.13 Depicted is the cooperation between the first leg 984A and the second leg 984B and the monopolar electrosurgical electrode 128. In this arrangement, the second end 132B can be compressed and fixed in place by the heat sink 458 and the optical structure 142.

[0158] Fig.13 An assembly of an optical structure 142 and a monopolar electrosurgical electrode 128 is depicted according to an example. Fig.13As shown, the electrosurgical electrode 128 has a longitudinal axis 1390 extending between a proximal end of the monopolar electrosurgical electrode 128 and a distal end of the monopolar electrosurgical electrode 128. The light sources 140 may be arranged circumferentially about the longitudinal axis 1390 of the monopolar electrosurgical electrode 128. Arranging the light sources 140 around the monopolar electrosurgical electrode 128 may help distribute light around the entire circumference of the monopolar electrosurgical electrode 128, which may help reduce shadows and provide more consistent illumination in all rotational alignment orientations of the monopolar electrosurgical electrode 128 relative to the handle 124 and / or the electrosurgical tool 112 relative to the target tissue.

[0159] In addition, the smoke exhaust channel 148 can extend through the aperture 1391 in the optical structure 142 and the PCB aperture 1392 in the second end 132B of the printed circuit board 132. This can help position the smoke exhaust channel 148 at the center of the shaft 126 (e.g., the central axis of the smoke exhaust channel 148 and the central axis of the shaft 126 can be colinear), which can enhance suction at the surgical site. In this arrangement, the electrosurgical tool 112 can provide illumination and suction around the perimeter of the monopolar electrosurgical electrode 128. In addition, integrating the optical structure 142 in this arrangement can improve the quality of illumination, reduce the size of the distal end of the electrosurgical tool, and improve the line of sight at the surgical site.

[0160] Reference again Figure 3 , the user input device 130 may include a first button 330A and a second button 330B located on an outer surface of the handle 124. In one embodiment, the first button 330A can be actuated to operate the electrosurgical tool 112 in a cutting operation mode, and the second button 330B can be actuated to operate the electrosurgical tool 112 in a coagulation operation mode. In this example, a third button (not shown) can be provided on the plug of the power cord 122 and / or on the electrosurgical generator 110, and the third button can be actuated to operate the light source 140 (i.e., to cause the light source 140 to emit light or stop emitting light). As described above, in other examples, the user input device 130 can be configured in different ways. For example, in other examples, the electrosurgical tool 112 can be operated in a fewer number of operation modes, a greater number of operation modes, and / or in different types of operation modes (e.g., such as the example operation modes described above). Additionally, for example, the at least one user input device 130 may additionally or alternatively include the user interface 116 of the electrosurgical generator 110 and / or another external device (e.g., a foot switch) for operating the electrosurgical tool 112 in one or more operating modes. Additionally, for example, the user input device 130 on the handle 124 may include a third button for operating the light source 140.

[0161] Despite Figure 3-13The electrosurgical tool 112 shown in FIG. 1 includes a smoke exhaust passage 148 , a light source 140 , and an optical structure 142 , but in other embodiments, the electrosurgical tool 112 may omit one or more of these components.

[0162] Figure 14-21 Other components of the electrosurgical tool 112 are depicted according to additional or alternative examples. Specifically, Fig.14 A side view of the electrosurgical tool 112 is shown with a first portion of the handle 124 omitted for illustration purposes. Fig.15 A first perspective view of an electrosurgical tool 112 is shown with a second portion of the handle 124 (opposite the first portion of the handle 124) omitted for illustration purposes, Fig.16 A second perspective view of the electrosurgical tool 112 is shown with the second portion of the handle 124 omitted for illustration purposes. Fig.17 An electrosurgical tool 112 is shown with the first and second portions of the handle 124 omitted for illustration purposes. Fig.18 An exploded view of the stop assembly 1793 of the electrosurgical tool 112 is shown, Fig.19 A shaft stop 1794 of a stop assembly 1793 according to an example is shown, and Fig. 20 A partial cross-sectional view of the connection between the shaft stop 1794 and the shaft 126 is shown, and Fig.21 A swivel nut 1795 is depicted according to an example.

[0163] like Figure 15-16 As shown, a portion of the printed circuit board 132 can be fixedly coupled to the inner wall 1524 of the handle 124. The portion of the printed circuit board 132 that is coupled to the inner wall 1524 of the handle 124 can be a portion of the printed circuit board 132 that is located outside the inner hole 254 of the shaft 126. Fixedly coupling the printed circuit board 132 to the inner wall 1524 of the handle 124 can help reduce or prevent tangling and / or wrinkling of the printed circuit board 132 when the shaft 126 moves longitudinally relative to the handle 124.

[0164] As an example, Fig.15 An area 1501 is indicated on the inner wall 1524 of the handle 124 to which the printed circuit board 132 may be fixedly coupled. The area 1501 may be disposed along the longitudinal axis 350 (eg, Figure 3 This can help increase the surface area of ​​the connection between the printed circuit board 132 and the inner wall 1524 of the handle 124, thereby enhancing the strength of the connection between the printed circuit board 132 and the inner wall 1524 of the handle 124.

[0165] In some examples, the surface roughness of region 1501 can be greater than the surface roughness of another portion of the interior wall 1524 of the handle 124 surrounding region 1501. For example, in one embodiment, the manufacturing process can include roughening the interior wall 1524 at region 1501 (e.g., by sanding, heat, chemical etching, and / or sandblasting) and not roughening other portions of the interior wall 1524. In another embodiment, the manufacturing process can include reducing the roughness of other portions of the interior wall 1524 and maintaining the surface roughness of region 1501. By providing region 1501 with an increased surface roughness relative to other portions of the interior wall 1524, the region 1501 can enhance the coupling of the printed circuit board 132 and the handle 124 and / or the region 1501 can provide a tactile indication of the proper coupling position to the assembler during the manufacturing process.

[0166] exist Figure 14-20 In the example shown, the electrosurgical tool 112 is configured to define a limited range of rotation between the shaft 126 and the handle 124. Limiting the range of rotation between the shaft 126 and the handle 124 can help alleviate excessive stress on the printed circuit board 132 caused by excessive rotation of the shaft 126 relative to the handle 124. As described above, in one embodiment, the monopolar electrosurgical electrode 128 can be rotated more than 360 degrees relative to the handle 124. This can improve ease of use by allowing the operator to freely rotate the monopolar electrosurgical electrode 128 without restriction. However, in other embodiments, the monopolar electrosurgical electrode 128 can be rotated less than or equal to 360 degrees (e.g., rotatable 180 degrees or rotatable 360 ​​degrees). This can still allow the operator to achieve the desired rotational arrangement orientation, but the operator may rotate in a first direction, reach a stop point that limits further rotation, and then rotate back in a second direction to achieve the desired rotational arrangement orientation.

[0167] exist Figure 14-20 In the illustrated example, the electrosurgical tool 112 includes a stop assembly 1793 configured to limit the range of rotational movement between the shaft 126 and the handle 124 to a predetermined range of rotational movement. Figure 14-20 In the embodiment, the stop assembly 1793 is configured to provide a rotational range of motion of approximately 400 degrees relative to each other for the shaft 126 and the handle 124. However, as described above, the stop assembly 1793 can be configured to allow the shaft 126 and the handle 124 to have a different rotational range of motion relative to each other.

[0168] like Figure 17-18 As shown, the stop assembly 1793 includes the shaft 126, the shaft stop 1794 and the rotation nut 1795. In this example, the shaft stop 1794 is fixedly coupled to the proximal portion of the shaft 126, and the rotation nut 1795 is rotatably coupled to the shaft stop 1794. Figure 14-16 As shown, the rotation nut 1795 is rotationally fixed relative to the handle 124, but is axially movable relative to the handle 124. As described in further detail below, the rotational coupling between the shaft stop 1794 and the rotation nut 1795 limits the range of motion of the shaft 126 relative to the handle 124.

[0169] like Fig.19 As shown, the shaft stopper 1794 includes a through hole 1994A extending between a proximal end 1994B and a distal end 1994C of the shaft stopper 1794, a shaft coupling mechanism 1994D, and external threads 1994E. The through hole 1994A is configured to receive the proximal portion of the shaft 126, so that the shaft stopper 1794 surrounds the proximal portion of the shaft 126, as shown in FIG. Fig.17 and 20 shown.

[0170] The shaft coupling mechanism 1994D is configured to fixedly couple the shaft stop 1794 to the proximal portion of the shaft 126. Fig.19 In, for example, the shaft coupling mechanism 1994D includes a plurality of tabs that are configured to engage and couple to a plurality of apertures 1896 on the proximal portion of the shaft 126 when the proximal portion of the shaft 126 is received in the through hole 1994A of the shaft stop 1794. Fig.18 Aperture 1896 is shown on the proximal portion of shaft 126, and Fig. 20 The tab of the shaft coupling mechanism 1994D is shown engaging the aperture 1896 to rotationally and axially secure the shaft stop 1794 relative to the shaft 126 .

[0171] The shaft stopper 1794 is rotationally coupled to the rotating nut 1795. For example, as Fig.21 As shown, the rotation nut 1795 may include an internal thread 2195A that may threadably engage the external thread 1994E of the shaft stop 1794. The range of motion between the shaft 126 and the handle 124 corresponds to the range of motion between the shaft stop 1794 and the rotation nut 1795, which is defined by the external thread 1994E of the shaft stop 1794 and the internal thread 2195A of the rotation nut 1795. For example, the range of motion may be defined by the length and / or number of turns of the external thread 1994E and / or the internal thread 2195A.

[0172] See also Fig.21 , the rotating nut 1795 may include one or more protrusions 2195B that are configured to help prevent the rotating nut 1795 from rotating relative to the handle 124 and to allow the rotating nut 1795A to move axially relative to the handle 124. For example, as Figure 15-16As shown, the handle 124 may include one or more longitudinal slots 1597, each of which is configured to receive a corresponding one of the protrusions 2195B of the rotating nut 1795A. The longitudinal slots 1597 extend in the longitudinal direction (e.g., parallel to Figure 3 The longitudinal axis 350 shown in FIG. 15 is a longitudinal axis 350 of the embodiment shown in FIG. 15, which has a length greater than or equal to the length by which the shaft 126 can move axially relative to the handle 124. In this arrangement, the engagement between the protrusion 2195B and the longitudinal slot 1597 prevents the rotation nut 1795 from rotating relative to the handle 124, but allows the rotation nut 1795 to move axially relative to the handle 124.

[0173] exist Figure 14-21 In the embodiment, the handle 124 includes two longitudinal grooves 1597 on the upper inner surface 1598 and two longitudinal grooves 1597 on the lower inner surface 1698. Fig.21 As shown, the rotating nut 1795 includes two corresponding protrusions 2195B on the upper outer surface, which are configured to cooperate with the two longitudinal grooves 1597 on the upper inner surface 1598, and two corresponding protrusions 2195B on the lower outer surface, which are configured to cooperate with the two longitudinal grooves 1597 on the lower inner surface 1698. Figure 14-16 The projection 2195B is shown positioned in the longitudinal slot 1597 of the handle 124. In this arrangement, the spin nut 1795 (i) moves axially with the shaft 126 (e.g., due to the coupling between the spin nut 1795 and a shaft stop 1794 fixedly coupled to the shaft 126), (ii) is prevented from rotating relative to the handle 124 due to the engagement between the projection 2195B and the longitudinal slot 1597, and (iii) rotation of the shaft 126 and handle 124 is constrained to a predetermined range of rotational movement by threaded engagement with the shaft stop 1794 while being rotationally fixed relative to the handle 124.

[0174] exist Figure 14-21In the embodiment, the rotating nut 1795 is C-shaped (e.g., the inner surface of the hole of the rotating nut 1795 does not extend over the entire circumference of the hole of the rotating nut 1795). For example, the inner surface of the rotating nut 1795 and the outer surface of the rotating nut 1795 can extend arcuately from about 270 degrees to about 350 degrees around the central axis of the hole through the rotating nut 1795. In this arrangement, the rotating nut 1795 can have opposing terminals that define an opening through the lateral wall of the rotating nut 1795 (e.g., between the hole of the rotating nut 1795 and the outside of the hole). For example, this can facilitate assembly. For example, the C-shaped shape of the rotating nut 1795 can cause the rotating nut 1795 to deform and / or bend to increase the size of the opening between the two terminals so that the shaft stopper 1794 can be inserted into the hole of the rotating nut 1795 through the opening. After the shaft stopper 1794 is inserted into the hole of the rotating nut 1795 through the opening, the rotating nut 1795 can be elastically reduced in size again around the shaft stopper 1794. In some examples, the shaft stopper 1794 can be inserted through the opening on the rotating nut 1795 with the printed circuit board 132 located in the through hole 1994A of the shaft stopper 1794.

[0175] Fig.46 A cross-sectional view through the handle 124, the shaft stop 1794, and the spin nut 1795 of the electrosurgical tool 112 is shown according to another example. Fig.46 The example shown in Figure 14-21 The example shown and described differs in that the protrusion 2195B and the longitudinal slot 1597 for non-rotational engagement between the handle 124 and the swivel nut 1795 have the same Figure 17-21 Different configurations of similar features as shown in . For example, Fig.46 As shown, each protrusion 2195B of the rotation nut 1795 can have a dovetail shape that is received in a corresponding longitudinal slot 1597 of the handle 124 having a corresponding dovetail shape. In this arrangement, the engagement between the protrusion 2195B and the longitudinal slot 1597 prevents the rotation nut 1795 from rotating relative to the handle 124 and allows the rotation nut 1795 to move axially relative to the handle 124, as described above with respect to the rotation nut 1795.

[0176] exist Fig.46 In the embodiment, the handle 124 includes a longitudinal groove 1597 on the upper inner surface 1598 and a longitudinal groove 1597 on the lower inner surface 1698. Fig.46As shown, the rotation nut 1795 includes a corresponding dovetail-shaped protrusion 2195B on the upper outer surface, which is configured to cooperate with the dovetail-shaped longitudinal groove 1597 on the upper inner surface 1598, and a corresponding dovetail-shaped protrusion 2195B on the lower outer surface, which is configured to cooperate with the dovetail-shaped longitudinal groove 1597 on the lower inner surface 1698. In this arrangement, the rotation nut 1795 (i) moves axially with the shaft 126 (e.g., due to the connection between the rotation nut 1795 and the shaft stop 1794 fixedly connected to the shaft 126), (ii) is prevented from rotating relative to the handle 124 due to the engagement between the protrusion 2195B and the longitudinal groove 1597, and (iii) is rotationally fixed relative to the handle 124 while limiting the rotation of the shaft 126 and the handle 124 to a predetermined range of rotational movement by threaded engagement with the shaft stop 1794.

[0177] Reference now Fig. 22 , a process 2200 of operating an electrosurgical tool according to an example is shown. Fig. 22 As shown, at block 2210, process 2200 includes coupling a power cord of an electrosurgical tool to an electrosurgical generator. The electrosurgical tool includes a handle defining an internal cavity, and a shaft extending distally from the internal cavity of the handle. The shaft defines an internal hole. The electrosurgical tool also includes a printed circuit board located in the internal hole of the shaft. The printed circuit board is electrically coupled to the power cord. The shaft is movable relative to the handle and the printed circuit board. The electrosurgical tool also includes an electrosurgical electrode extending distally from a distal end of the shaft.

[0178] At block 2212, process 2200 includes supplying electrosurgical energy from an electrosurgical generator to a printed circuit board using a power cord. At block 2214, process 2200 includes supplying electrosurgical energy from the power cord to an interior surface of the shaft through the printed circuit board. At block 2216, process 2200 includes conducting the electrosurgical energy from the shaft to an electrosurgical electrode.

[0179] Figure 23-33 Additional aspects of process 2200 according to other examples are described. Fig.23 As shown, process 2200 may also include, at block 2218, moving the shaft axially relative to the handle while maintaining an electrical connection between the printed circuit board and an interior surface of the shaft, and, at block 2220, folding a first portion of the printed circuit board onto a second portion of the printed circuit board in response to moving the shaft axially relative to the handle at block 2218.

[0180] like Fig.24As shown, process 2200 may include, at block 2222, rotating the shaft relative to the handle while maintaining an electrical connection between the printed circuit board and an interior surface of the shaft, and, at block 2224, winding the printed circuit board within at least one of an internal hole of the shaft or an internal cavity of the handle in response to rotating the shaft relative to the handle at block 2222.

[0181] like Fig.25 As shown, supplying electrosurgical energy from the power cord to the interior surface of the shaft via the printed circuit board at block 2214 may include electrically coupling the printed circuit board to the interior surface of the shaft via brushes at block 2226.

[0182] like Fig.26 As shown, electrically coupling the printed circuit board to the interior surface of the shaft via the brushes at block 2226 may include, at block 2228, pressing the printed circuit board between the brushes and a heat sink in the interior bore of the shaft.

[0183] like Fig. 27 As shown, process 2200 may also include, at block 2230, axially retaining the brush in a groove extending along at least a portion of a circumference of the heat sink.

[0184] like Fig.28 As shown, process 2200 may also include coupling the brushes, the printed circuit board, and the heat sink to each other via attachment members at block 2232 .

[0185] like Fig.29 As shown, supplying electrosurgical energy from the power cord to the interior surface of the shaft via the printed circuit board at block 2214 may include forcing conductive contacts of the printed circuit board into contact with the interior surface of the shaft via a biasing member at block 2234 .

[0186] like Fig.30 As shown, process 2200 may also include, at block 2236, using a biasing member to prevent fluid from entering a space between an interior surface of the shaft and the heat sink.

[0187] like Fig.31 As shown, process 2200 may also include, at block 2238, using a printed circuit board to transmit direct current (DC) power from a DC power source to a light source in the interior bore of the shaft.

[0188] like Fig.32 As shown, process 2200 may also include, at block 2240, rotating the shaft relative to the smoke exhaust passage in the interior bore of the shaft.

[0189] like Fig.33 As shown, process 2200 may also include limiting rotation of the shaft relative to the handle to a predetermined range of rotational movement via a stop assembly of the electrosurgical tool at block 2242 .

[0190] Reference now Fig.34 , a process 3400 for manufacturing an electrosurgical tool according to an example is shown. Fig.34 As shown, at block 3410, process 3400 includes forming a housing including a handle defining an internal cavity and a shaft extending distally from the internal cavity of the handle. The shaft defines an internal hole. At block 3412, process 3400 includes positioning a printed circuit board in the internal hole of the shaft. At block 3414, process 3400 includes electrically coupling the printed circuit board to a power cord. The power cord is configured to be coupled to an electrosurgical generator and receive electrosurgical energy from the electrosurgical generator. The shaft is movable relative to the handle and the printed circuit board. At block 3416, process 3400 includes electrically coupling the printed circuit board to an internal surface of the shaft. At block 3418, process 3400 includes electrically coupling an electrosurgical electrode to a distal end of the shaft. The shaft is configured to conduct electrosurgical energy to the electrosurgical electrode.

[0191] Figure 35-45 Other aspects of process 3400 according to other examples are described. Fig.35 As shown, process 3400 may include positioning a heat sink in an inner bore of the shaft at block 3420. In addition, Fig.35 , positioning the printed circuit board in the internal bore of the shaft at block 3412 may include positioning the printed circuit board between the heat sink and the shaft at block 3422 .

[0192] like Fig.36 As shown, positioning the printed circuit board in the inner bore of the shaft at block 3412 may include positioning at least a portion of the printed circuit board in a groove of the heat sink at block 3424. The groove may extend along at least a portion of the perimeter of the heat sink.

[0193] like Fig.37 As shown, electrically coupling the printed circuit board to the interior surface of the shaft at block 3416 may include electrically coupling brushes to the printed circuit board and the interior surface of the shaft at block 3426 .

[0194] like Fig.38 As shown, process 3400 may also include, at block 3428, positioning the brushes along at least half of the circumference of the heat sink.

[0195] like Fig.39 As shown, process 3400 may also include coupling an attachment member around the brushes, printed circuit board, and heat sink at block 3430 .

[0196] like Fig.40 As shown, coupling the attachment member to the brushes, printed circuit board, and heat sink at block 3430 may include applying heat to a heat shrink material of the attachment member at block 3432 .

[0197] like Fig.41 As shown, electrically coupling the printed circuit board to the interior surface of the shaft at block 3416 may include, at block 3434, forcing the printed circuit board into contact with the interior surface of the shaft using a biasing member in a groove extending along at least a portion of the perimeter of the heat sink.

[0198] like Fig.42 As shown, process 3400 may also include forming a conductive contact on the printed circuit board at block 3436. The width of the printed circuit board at the conductive contact is greater than the width of the printed circuit board at the first section of the printed circuit board proximal to the conductive contact and at the second section of the printed circuit board distal to the conductive contact.

[0199] like Fig.43 As shown, process 3400 may also include coupling a light source to a second end of the printed circuit board at block 3438. The printed circuit board may have a first end and the second end, the printed circuit board may be elongated in an axial dimension extending between the first end and the second end, and the axial dimension may be parallel to the longitudinal axis of the shaft.

[0200] like Fig.44 As shown, process 3400 may also include, at block 3440, fixedly coupling a portion of the printed circuit board to an area of ​​an interior wall of the housing.

[0201] like Fig.45 As shown, process 3400 may also include roughening the interior wall at the region and not roughening another portion of the interior wall surrounding the region at block 3442 .

[0202] For the purpose of illustration and description, descriptions of different advantageous arrangements have been given, and are not intended to be exhaustive or limited to examples of the disclosed form. Many modifications and variations will be apparent to those of ordinary skill in the art. In addition, different advantageous examples may describe different advantages compared to other advantageous examples. The selected one or more examples are selected and described to explain the principles of these examples, their practical applications, and to enable those of ordinary skill in the art to understand that the various examples of the present disclosure with various modifications are suitable for the intended specific use.

[0203] In addition, it is contemplated that any optional features of the described variations of the invention may be described and claimed independently or in combination with any one or more features described herein. Similarly, the absence of a quantifier modifier also includes the possibility of a plurality of identical items. More specifically, in this document and the appended claims, the absence of a quantifier modifier includes a plural reference unless the context clearly dictates otherwise. It should also be noted that the claims may be written to exclude any optional elements. Therefore, this statement is intended to serve as a prior basis for the use of exclusive terminology such as "only", "only" or the use of "negative" restrictions when reciting claim elements. Unless otherwise defined herein, all technical and scientific terms used herein have the same meaning as those generally understood by those of ordinary skill in the art to which the invention belongs. The breadth of this application is not limited by the subject specification, but only by the plain interpretation of the claimed terms adopted.

Claims

1. An electrosurgical tool comprising: a handle defining an interior cavity; a power cord configured to couple to the electrosurgical generator and receive electrosurgical energy from the electrosurgical generator; a shaft extending distally from the interior cavity of the handle, wherein the shaft defines an interior bore; a printed circuit board in the interior bore of the shaft, wherein the printed circuit board is electrically coupled to the power cord, wherein the printed circuit board is configured to conduct electrosurgical energy from the power cord to the interior surface of the shaft, wherein the shaft is movable relative to the handle and the printed circuit board; and An electrosurgical electrode extends distally from the distal end of the shaft, wherein the shaft is configured to conduct electrosurgical energy to the electrosurgical electrode.

2. The electrosurgical tool of claim 1, wherein the shaft has at least one of the following: (i) rotatable relative to the handle and the printed circuit board, or (ii) telescopically movable relative to the handle and the printed circuit board.

3. The electrosurgical tool according to any one of claims 1-2, further comprising a heat sink in the inner bore of the shaft, and The printed circuit board is located between the heat sink and the shaft.

4. An electrosurgical tool according to claim 3, wherein the heat sink includes a groove extending along at least a portion of the perimeter of the heat sink, At least a portion of the printed circuit board is located in the groove of the heat sink.

5. The electrosurgical tool of claim 4, further comprising a brush electrically coupling the printed circuit board to the interior surface of the shaft.

6. An electrosurgical tool according to claim 5, wherein the brush extends along at least half of the circumference of the heat sink.

7. The electrosurgical tool of any one of claims 5-6, further comprising an attachment member coupling the brush, the printed circuit board, and the heat sink to one another.

8. An electrosurgical tool according to claim 7, wherein the attachment member is a band formed of a heat shrink material.

9. The electrosurgical tool according to any one of claims 5 to 8, wherein the brush comprises a distal end, a proximal end and a central portion between the distal end and the proximal end, wherein the central portion has a shape corresponding to the shape of the conductive contact of the printed circuit board in the recess of the heat sink, and The distal end of the brush and the proximal end of the brush extend radially outward from the central portion to directly contact the inner surface of the shaft.

10. The electrosurgical tool of claim 3, further comprising a biasing member located in a groove extending along at least a portion of the perimeter of the heat sink, wherein the biasing member is located between the heat sink and the printed circuit board, and Wherein a biasing member forces the printed circuit board into contact with the interior surface of the shaft.

11. An electrosurgical tool according to claim 10, wherein the biasing member is an O-ring.

12. An electrosurgical tool according to any one of claims 10-11, wherein the biasing member extends along the entire circumference of the heat sink and provides a gasket that prevents fluid from entering the space between the interior surface of the shaft and the heat sink.

13. An electrosurgical tool according to any one of claims 1 to 12, wherein the printed circuit board has a first end and a second end, wherein the printed circuit board is elongated in an axial dimension extending between the first end and the second end, and The axial dimension is parallel to the longitudinal axis of the shaft.

14. An electrosurgical tool according to claim 13, wherein the printed circuit board includes conductive contacts for electrically coupling the printed circuit board to the interior surface of the shaft, and The conductive contact is located between the first end and the second end of the printed circuit board.

15. An electrosurgical tool according to claim 14, wherein the width of the printed circuit board at the conductive contact is greater than the width of the printed circuit board at a first section of the printed circuit board proximal to the conductive contact and at a second section of the printed circuit board distal to the conductive contact.

16. The electrosurgical tool of claim 15, wherein the conductive contacts have a triangular shape.

17. An electrosurgical tool according to any one of claims 14-16, wherein the printed circuit board includes a light source located at the second end of the printed circuit board.

18. An electrosurgical tool according to any one of claims 14-17, wherein the printed circuit board includes a plurality of switches actuatable by a plurality of buttons on the handle to control the electrosurgical energy supplied to the electrosurgical electrode.

19. The electrosurgical tool of any one of claims 1-18, further comprising a smoke exhaust passage located in the interior bore of the shaft, wherein the smoke exhaust passage is rotationally fixed relative to the handle.

20. An electrosurgical tool according to any one of claims 1-19, wherein rotation of the shaft relative to the handle causes corresponding rotation of the electrosurgical electrode relative to the handle.

21. An electrosurgical tool according to any one of claims 1-20, wherein the printed circuit board is a flexible printed circuit board.

22. An electrosurgical tool according to any one of claims 1-21, wherein a portion of the printed circuit board is fixedly coupled to an interior wall of the hand handle.

23. An electrosurgical tool according to claim 22, wherein the portion of the printed circuit board is fixedly coupled to a region of the interior wall of the handle, and wherein the region is elongated along a longitudinal axis of the electrosurgical tool.

24. An electrosurgical tool according to claim 22, wherein the portion of the printed circuit board is fixedly coupled to a region of an inner wall of the handle, and wherein a surface roughness of the region is greater than a surface roughness of another portion of the inner wall surrounding the region.

25. The electrosurgical tool of any one of claims 1-24, further comprising a stop assembly configured to limit the range of rotational movement between the shaft and the handle to a predetermined range of rotational movement.

26. An electrosurgical tool as claimed in claim 25, wherein the predetermined range of rotational movement is approximately 400 degrees.

27. The electrosurgical tool of any one of claims 25-26, wherein the stop assembly comprises: a shaft stop fixedly coupled to the proximal portion of the shaft; as well as A swivel nut is (i) rotatably coupled to the shaft stop, (ii) rotationally fixed relative to the handle, and (iii) axially movable relative to the handle.

28. The electrosurgical tool of claim 27, wherein the shaft stop comprises external threads, and the rotation nut comprises internal threads threadably engageable with the external threads of the shaft stop, and The predetermined range of motion between the shaft and the handle corresponds to a range of motion between the shaft stopper and the rotating nut defined by the external thread of the shaft stopper and the internal thread of the rotating nut.

29. An electrosurgical tool according to any one of claims 27-28, wherein the shaft stop includes a plurality of tabs, which are configured to engage and connect to a plurality of apertures on the proximal portion of the shaft when the proximal portion of the shaft is received in the through hole of the shaft stop.

30. The electrosurgical tool of any one of claims 27-29, wherein the rotation nut comprises a plurality of protrusions, wherein the handle includes a plurality of longitudinal slots, each longitudinal slot being configured to receive a corresponding one of the protrusions of the swivel nut, and The engagement between the plurality of protrusions and the plurality of longitudinal slots prevents the rotation of the swivel nut relative to the handle and allows the swivel nut to move axially relative to the handle.

31. An electrosurgical tool as claimed in claim 30, wherein each protrusion has a dovetail shape and each longitudinal slot has a dovetail shape.

32. A method of operating an electrosurgical tool, comprising: A power cord of an electrosurgical tool is coupled to the electrosurgical generator, wherein the electrosurgical tool comprises: a handle defining an internal cavity, a shaft extending distally from the interior cavity of the handle, wherein the shaft defines an interior bore; a printed circuit board in the interior bore of the shaft, wherein the printed circuit board is electrically coupled to the power cord, wherein the shaft is movable relative to the handle and the printed circuit board; an electrosurgical electrode extending distally from the distal end of the shaft; supplying electrosurgical energy from an electrosurgical generator to the printed circuit board using a power cord; supplying electrosurgical energy from a power cord to an interior surface of the shaft through the printed circuit board; and Electrosurgical energy is transmitted from the shaft to the electrosurgical electrodes.

33. The method of claim 32, further comprising: moving the shaft axially relative to the handle while maintaining electrical connection between the printed circuit board and the interior surface of the shaft; and In response to the shaft moving axially relative to the handle, the first portion of the printed circuit board is folded over the second portion of the printed circuit board.

34. The method according to any one of claims 32-33, further comprising: rotating the shaft relative to the handle while maintaining an electrical connection between the printed circuit board and the interior surface of the shaft; and In response to rotating the shaft relative to the handle, the printed circuit board is wound within at least one of the internal bore or the internal cavity of the shaft.

35. The method of any one of claims 32-24, wherein supplying electrosurgical energy from the power cord to the interior surface of the shaft through a printed circuit board comprises electrically coupling the printed circuit board to the interior surface of the shaft through brushes.

36. The method of claim 35, wherein electrically coupling the printed circuit board to the interior surface of the shaft via the brushes comprises pressing the printed circuit board between the brushes and a heat sink in the interior bore of the shaft.

37. The method of any of claims 35-36, further comprising retaining the brush axially in a groove extending along at least a portion of the circumference of the heat sink.

38. The method of any one of claims 35-37, further comprising coupling the brush, the printed circuit board, and the heat sink to each other via an attachment member.

39. The method of any one of claims 32-34, wherein supplying electrosurgical energy from the power cord to the interior surface of the shaft through the printed circuit board comprises forcing conductive contacts of the printed circuit board into contact with the interior surface of the shaft via a biasing member.

40. The method of claim 39, wherein the biasing member is located in a groove extending along at least a portion of the circumference of the heat sink in the interior bore of the shaft, The biasing member is located between the heat sink and the printed circuit board.

41. The method of any one of claims 39-40, further comprising using a biasing member to prevent fluid from entering a space between an interior surface of the shaft and the heat sink.

42. The method of any one of claims 32-41, further comprising transmitting direct current (DC) power from a DC power source to a light source in the interior bore of the shaft using a printed circuit board.

43. The method of any one of claims 32-42, further comprising rotating the shaft relative to the smoke exhaust passage in the interior bore of the shaft.

44. The method of any one of claims 32-43, further comprising limiting rotation of the shaft relative to the handle within a predetermined range of rotational movement via a stop assembly of the electrosurgical tool.

45. A method of manufacturing an electrosurgical tool, comprising: forming a housing including a handle defining an interior cavity and a shaft extending distally from the interior cavity of the handle, wherein the shaft defines an interior bore; Position the PCB in the inner hole of the shaft, electrically coupling the printed circuit board to a power cord, wherein the power cord is configured to couple to an electrosurgical generator and receive electrosurgical energy from the electrosurgical generator, wherein the shaft is movable relative to the handle and the printed circuit board; electrically coupling the printed circuit board to the interior surface of the shaft; as well as An electrosurgical electrode is electrically coupled to the distal end of the shaft, wherein the shaft is configured to conduct electrosurgical energy to the electrosurgical electrode.

46. ​​The method of claim 45, wherein the shaft is at least one of: (i) rotatable relative to the handle and the printed circuit board, or (ii) telescopically movable relative to the handle and the printed circuit board.

47. The method of any one of claims 45-46, further comprising positioning a heat sink in the interior bore of the shaft, Wherein positioning the printed circuit board in the interior bore of the shaft includes positioning the printed circuit board between a heat sink and the shaft.

48. The method of claim 47, wherein the heat sink includes a groove extending around at least a portion of the length of the heat sink, Wherein positioning the printed circuit board within the interior bore of the shaft includes positioning at least a portion of the printed circuit board within a recess of the heat sink.

49. The method of claim 48, wherein electrically coupling the printed circuit board to the interior surface of the shaft comprises electrically coupling brushes to the printed circuit board and the interior surface of the shaft.

50. The method of claim 49, further comprising positioning the brushes along at least half of the circumference of the heat sink.

51. The method of any of claims 49-50, further comprising coupling an attachment member around the brushes, the printed circuit board, and the heat sink.

52. The method of claim 51, wherein coupling the attachment member about the brushes, the printed circuit board, and the heat sink comprises applying heat to a heat shrink material of the attachment member.

53. The method of any one of claims 45-48, wherein electrically coupling the printed circuit board to the interior surface of the shaft comprises forcing the printed circuit board into contact with the interior surface of the shaft using a biasing member located in a groove extending along at least a portion of the perimeter of the heat sink.

54. The method of claim 53, wherein the biasing member is an O-ring.

55. The method according to any one of claims 45-54 also includes forming a conductive contact on a printed circuit board, wherein the width of the printed circuit board at the conductive contact is greater than the width of the printed circuit board at a first section of the printed circuit board proximal to the conductive contact and at a second section of the printed circuit board distal to the conductive contact.

56. The method of any one of claims 45-55, further comprising coupling a light source to the second end of the printed circuit board, wherein the printed circuit board has a first end and a second end, wherein the printed circuit board is elongated in an axial dimension extending between the first end and the second end, and The axial dimension is parallel to the longitudinal axis of the shaft.

57. The method of any one of claims 45-56, wherein the printed circuit board is a flexible printed circuit board.

58. The method of any one of claims 45-57, further comprising fixedly coupling a portion of the printed circuit board to a region of an interior wall of the housing.

59. The method of claim 58, further comprising roughening the interior wall at the region and not roughening another portion of the interior wall surrounding the region.

Images