Electrosurgical energy harvesting

Abstract

The present invention provides an electrosurgical device configured to harvest RF energy to power one or more loads. The electrosurgical device includes a distal portion having two electrodes configured to introduce an electrical current into tissue and a proximal portion coupled to an electrical connector. The electrical connector is configured to provide a treatment signal and a continuous signal to an energy harvesting assembly housed within the electrosurgical device. The energy harvesting assembly includes a transformer configured to isolate the treatment signal and reduce the treatment signal to a lower voltage, an AC-DC converter configured to convert an AC signal to DC, and a DC-DC regulator configured to output a fixed voltage. The one or more loads may be electrically coupled to the energy harvesting assembly such that the one or more loads are powered by the fixed voltage.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims the benefit of U.S. Provisional Application Serial No. 63 / 358,382, filed on July 5, 2022, the disclosure of which is incorporated herein by reference. Technical Field

[0003] Embodiments of the present disclosure relate generally to the field of electrosurgical energy delivery, and more particularly to harvesting therapy signals useful in electrosurgery to power an electrosurgical handpiece load. Background Art

[0004] Electrosurgical devices for applying electrical energy to tissue are commonly used in surgical procedures for hemostatic sealing and coagulation of soft tissue and bone at the surgical site. Such electrosurgical devices can be used in, but are not limited to, orthopedic surgery, spinal surgery, thoracic surgery, and open abdominal surgery.

[0005] An electrosurgical device may include a handpiece having a distal mounting end including one or more electrodes. The one or more electrodes may be positioned against tissue so that an electrical current is introduced into the tissue. The heat generated may be used to cut, coagulate, or induce metabolic processes in the target tissue. An electrosurgical generator typically provides power and electrical energy in the form of radio frequency ("RF") energy to one of two handpiece topologies, monopolar and bipolar.

[0006] During monopolar operation, current is introduced into the tissue through the active electrode and returned through a return electrode located separately on the patient's body. Therefore, a monopolar handpiece has only one wire for the therapy signal in the monopolar connector and a second contact called the return signal in a different connector called the return pad connector.

[0007] During bipolar operation, current is introduced into the tissue through the active electrode and returned from the tissue through the return electrode. Therefore, the bipolar handpiece provides the two electrodes required for treatment to the bipolar connector. To achieve this, bipolar handpieces typically use a 3-pin connector that can provide a high-power treatment signal and a continuous low-power signal.

[0008] Conventional electrosurgical devices used for electrosurgical tissue treatment face a number of challenges that can vary for different protocols. Some of the challenges that arise are inconsistent lighting of the treatment area and the inability to verify that the electrosurgical device is compatible with a specific electrosurgical generator. Traditional solutions to these problems typically require additional wiring or the inclusion of batteries within the electrosurgical device. These approaches increase costs and may require the purchase of new equipment.

[0009] Therefore, improved systems and methods are desired to enhance the capabilities of an electrosurgical device without changing the generator or requiring a second electrical connection to the electrosurgical device. Summary of the invention

[0010] The disclosed technology generally relates to an electrosurgical device configured to enable energy to be extracted from both detection and therapy signals to power accessories in order to increase the functionality of the electrosurgical device without requiring any changes to the wiring or electrosurgical generator.

[0011] In one aspect, the present disclosure provides an electrosurgical device configured to collect RF energy to power one or more loads. The electrosurgical device may include a distal portion and a proximal portion. The distal portion may include two electrodes configured to introduce current into tissue. The proximal portion may be coupled to an electrical connector configured to provide a therapeutic signal and a continuous signal to an energy collection component housed in the electrosurgical device. The energy collection component may include a transformer configured to reduce the therapeutic signal to a lower voltage, an AC-DC converter configured to convert the AC signal to DC, and a DC-DC regulator configured to output a fixed voltage. One or more loads may be electrically coupled to the energy collection component so that the one or more loads are powered by a fixed voltage.

[0012] The details of one or more aspects of the present disclosure are set forth in the following drawings and description. Other features, objectives, and advantages of the techniques described in the present disclosure will be apparent from the description and drawings, and from the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0013] The subject matter of the present invention may be more fully understood when the following detailed description of various embodiments is considered in conjunction with the accompanying drawings, in which:

[0014] Figure 1 is a schematic diagram depicting an electrosurgical device according to the prior art.

[0015] Figure 2 is a schematic diagram depicting an electrosurgical device according to an embodiment.

[0016] Figure 3 is a flow chart of a method for powering a load of an electrosurgical device, according to an embodiment.

[0017] Although various embodiments may adopt various modifications and alternative forms, details thereof have been shown by way of example in the drawings and will be described in detail. However, it should be understood that it is not intended to limit the claimed invention to the specific embodiments described. On the contrary, it is intended to cover all modifications, equivalents, and alternatives that fall within the spirit and scope of the subject matter as defined by the claims. DETAILED DESCRIPTION

[0018] Figure 1 1 is a partial schematic diagram of an electrosurgical device 100 configured to transmit RF energy at a treatment site to provide hemostatic sealing and coagulation of soft tissue and bone. The electrosurgical device 100 includes a connector 102 and a bipolar handpiece 104 having two electrodes 106 .

[0019] The connector 102 includes a large pin 108 and a small pin 110, and is configured to be in electrical communication with an electrosurgical generator (not shown) and the proximal end of the bipolar hand piece 104, so that the power signal is delivered to the electrode 106 at the distal end of the bipolar hand piece 104. In an embodiment, the connector 102 can be a 3-pin connector capable of providing a high-power treatment signal and a low-power continuous signal via a cable 114. The large pin 108 is used for the high-power treatment signal, while the small pin 110 uses a low-power continuous signal to detect a button press on the hand piece. When the button is pressed, the circuit is closed by the switch 112 and the treatment signal is provided. In an embodiment, an example of a treatment signal is 469KHz and 20W to 220W, and an example of a continuous signal is 47KHz.

[0020] It should be understood that the terms "proximal" and "distal" as used herein are in reference to a clinician grasping a handpiece. Thus, the electrode 106 is located distally relative to the more proximal handle or grip portion of the bipolar handpiece 104. However, surgical devices are used in many orientations and positions, and these terms are not intended to be limiting and absolute.

[0021] Figure 2 A schematic diagram of an electrosurgical device 200 is depicted that is configured to convert a small portion of an RF signal used to treat tissue or to detect a button press into a DC voltage. The DC voltage may be used to power a load 216 of the electrosurgical device, such as one or more LEDs, a microprocessor, and a timer.

[0022] The electrosurgical device 200 includes a connector 202 and a bipolar handpiece 204 having two electrodes 206. The connector 202 includes a large pin 208 and a small pin 210 and is configured to be compatible with an existing electrosurgical power source or bipolar energy supply. The cross-linked sealing energy provided by the AT&T® system (available from Medtronic Advanced Energy of Portsmouth, NH) is disclosed in U.S. Patent Nos. 6,558,385, 6,702,810, 6,953,461, 7,115,139, 7,311,708, 7,537,595, 7,645,277, and 7,811,282.

[0023] Thus, the electrosurgical device 200 is connected to an electrical energy source via the connector 202. Because the connector 202 is designed to be compatible with pre-existing generators, the pins are standardized based on the desired generator. In an embodiment, more or fewer large pins and short pins may be used, depending on the requirements of the generator. Thus, powering the load 216 without changing the connector 202 or the generator hardware enables the inclusion of additional functionality within the electrosurgical device 200 while maintaining compatibility with existing generators. In addition, the present disclosure minimizes the wiring from the electrosurgical device 200 so that it is not cumbersome in operation and storage. Selectively providing electrical energy to the electrosurgical device 200 may be achieved via an actuator on the handle at the proximal end of the handpiece 204. The switch 212 is associated with the actuator so that a therapeutic signal is provided to the electrode 206 when actuated. The electrical pathway within the bipolar handpiece 206 may be formed as a conductive arm, a wire, a trace, other conductive elements, and other electrical pathways formed by conductive materials such as metals, and may include stainless steel, titanium, gold, silver, platinum, or any other suitable material.

[0024] One aspect of the present disclosure is to include an energy harvesting component within electrosurgical device 200 that is configured to harvest energy from an electrical signal provided by a power source to power one or more loads 216 without affecting the operation of electrodes 206 .

[0025] The energy collection assembly may include a transformer 218, an AC-DC converter 220, and a DC-DC regulator 222. In an embodiment, the signal path may start from the button detection signal. The transformer 218 is used to reduce the high voltage treatment signal to a lower range acceptable to the DC circuit system, and at the same time isolate the DC circuit from the AC circuit. The AC-DC converter 220 may include any known device that converts an AC signal to DC, such as through a diode bridge and a capacitor. The DC-DC regulator 222 adjusts the output voltage of the energy collection assembly to a fixed value acceptable to one or more loads 216. When the electrosurgical device is in operation, the DC / DC regulator 222 is used due to the sensitivity to differences in voltage levels and power levels, because contact with tissue, bone or saline can cause large changes in the treatment signal. The energy collection assembly can accordingly reduce the high voltage RF treatment signal to a lower voltage without the need for a battery or an additional DC connection, such as USB.

[0026] In an embodiment, the effect of the load on the therapy signal can be adjusted by the amount of current used. For example, a typical minimum power for an electrosurgical device such as electrosurgical device 200 is 20W, and a load such as an LED may use less than 0.1W, well within the acceptable tolerances for electrosurgical devices (e.g., + / - 4W at 20W nominal power).

[0027] Embodiments of the present disclosure may operate with various form factors of the bipolar hand piece 204. In an embodiment, the bipolar hand piece 204 may include a distal shaft that separates the electrode 206 from the handle. The distal shaft may include a variety of materials and shapes so that the distal shaft is rigid, semi-rigid, or flexible, and the distal shaft may be angled, straight, or bendable. Regardless, the distal shaft may be sized and configured for a specific intended procedure or targeted area. In some embodiments, the distal shaft may be telescopic or retractable. In addition, the distal shaft may include an integral structure or may include a separately formed component that is permanently or removably joined. In an embodiment where the distal shaft and electrode 206 comprise a disposable portion of the electrosurgical device 200, the distal shaft may be separated from the bipolar hand piece 204.

[0028] Reference now Figure 3 , a method 300 of powering a load of an electrosurgical device using an RF signal is depicted according to an embodiment.

[0029] At 302, the high voltage therapy signal is brought to a lower range acceptable to the DC circuit system and the DC circuit is isolated from the AC circuit. In an embodiment, this can be achieved by adding a transformer.

[0030] At 304, the AC signal is converted to DC by using known circuits such as a diode bridge and a capacitor.

[0031] At 306, the output voltage is regulated to a fixed value acceptable to the load. In an embodiment, the voltage of the therapeutic signal may be susceptible to wide variations based on the generator settings or the state of the device tip in contact with tissue, air, or a saline bath. Because 302 and 304 are proportional circuits, all variations in the therapeutic signal will be converted to the input of 306, which then provides a regulated output based on the reference voltage.

[0032] It should be understood that, as long as the teaching remains operable, the various operations used in the method of the present teaching may be performed in any order and / or simultaneously. In addition, it should be understood that, as long as the teaching remains operable, the apparatus and method of the present teaching may include any number or all of the described embodiments.

[0033] When considering feasible loads for the energy harvesting assembly, there are several factors to consider. First, the amount of energy collected should not affect the performance of the therapeutic signal. Second, the DC power generated from the collected energy should be independent of the generator setting, which means that the voltage needs to remain regulated for all different power settings on the generator. Third, the DC power generated from the collected energy should be independent of the handpiece load, which means that the voltage needs to remain regulated for all different states of the handpiece (e.g., not in contact with tissue, in contact with tissue, different saline or blood conditions, etc.). Fourth, the cost of the additional circuitry should not exceed the use of batteries. Although the use of batteries is accompanied by different disadvantages, cost will be an important factor in whether the additional circuitry is feasible.

[0034] An example load of an energy harvesting component may be to increase lighting for better visibility at the distal tip of a handpiece. While some conventional handpieces may include LEDs, the LEDs are battery powered, resulting in limited and inconsistent light intensity over the battery life. In contrast, the use of existing therapeutic signals will provide unlimited power to low power loads such as one or more LEDs. In addition, the use of therapeutic signals eliminates the need for additional wiring and power sources (e.g., USB connections). The additional light at the tip of the electrosurgical device can greatly enhance the user's ability to use the electrosurgical device accurately. In addition, the LED can be used to provide an indication to the user (e.g., an LED indication or other visible indication). Such an indication can provide status information of the electrosurgical device or data of the indication collected or received by the electrosurgical device.

[0035] The low frequency button detection signal can also be used for energy harvesting of the load. The button detection signal can power a low current device such as an LED. In an embodiment utilizing both the treatment signal and the button detection signal, a continuous low level of light can be emitted from the LED, and the light can be intensified when the actuator of the handpiece is pressed. In an embodiment, a supercapacitor can be used to prevent the LED from flickering.

[0036] The memory and microprocessor are viable potential loads for the energy harvesting system of the present disclosure. The memory can be configured to store identification information of the electrosurgical device to enable detection of compatibility of the electrosurgical device with the power source. Such identification information may include, for example, a model number, a serial number, the number of operations in which the surgical instrument has been used, and / or any other type of information. In an embodiment, an RFID chip may be powered by the energy harvesting system to provide similar benefits.

[0037] The electrosurgical device may incorporate a low power communication component, such as Bluetooth Low Energy, to report this identification information. In some embodiments, the communication circuitry may transmit data acquired by one or more other loads of the energy harvesting system, such as a sensor (e.g., a temperature sensor). In an embodiment, an infrared receiver may be used for two-way communication.

[0038] In some cases, conventional generators may be limited in their ability to recognize the specific instrument configuration being used and optimize the control and diagnostic processes accordingly. From a compatibility perspective, this can make adding readable data circuitry to an electrosurgical device less than desirable. However, by implementing an accessory that supports this functionality through an existing USB connection on the generator, the generator can gain the necessary data reading functionality with minimal or no design changes. In other embodiments, information transmitted by the electrosurgical device can be received by a separate computing device.

[0039] Embodiments of the present disclosure may be applied to electrosurgical devices with additional functionality such as providing saline and / or suction to the treatment site. In such embodiments, the electrosurgical device may include a conduit, port, or channel and connected to a fluid source and / or pump. Providing suction and electrical energy to the tissue simultaneously advantageously allows for aspiration of debris and / or tissue cut by the electrode. Additional actuators may be included on the handpiece to control the flow or suction of fluid.

[0040] As previously described, the sensors may be supported by an energy harvesting system. The sensors may include one or more of proximity sensors, temperature sensors, humidity sensors, or other sensors. These sensors may be used to activate the saline or suction capabilities of the electrosurgical device.

[0041] In embodiments of the electrosurgical device that include a battery, the energy harvesting system can charge the battery. In some embodiments, this can enable the battery to power additional accessories than would otherwise be possible.

[0042] Other loads that may be supported by the energy harvesting system include: timers, which may be used to improve patient safety by indicating when prolonged contact with tissue has occurred; cameras, which may be used to improve navigation or provide a record of electrosurgical device usage; and speakers, which may be used to provide audio cues related to patient or device status.

[0043] Various embodiments of systems, devices, and methods have been described herein. These embodiments are given by way of example only and are not intended to limit the scope of the claimed invention. In addition, it should be understood that the various features of the embodiments described may be combined in various ways to produce many other embodiments. In addition, although various materials, sizes, shapes, configurations, and positions, etc. used with the disclosed embodiments have been described, other materials, sizes, shapes, configurations, and positions, etc. other than those disclosed may be utilized without exceeding the scope of the claimed invention.

[0044] Those of ordinary skill in the relevant art will recognize that the subject matter of the present invention may include fewer features than those shown in any of the above-described individual embodiments. The embodiments described herein are not meant to be an exhaustive presentation of the manner in which the various features of the subject matter of the present invention may be combined. Therefore, these embodiments are not mutually exclusive combinations of features; on the contrary, as understood by those of ordinary skill in the art, each embodiment may include a combination of different individual features selected from different individual embodiments. In addition, unless otherwise indicated, the elements described with respect to one embodiment may be implemented in other embodiments, even if these elements are not described in such embodiments.

[0045] Although dependent claims may refer to specific combinations with one or more other claims in the claims, other embodiments may also include combinations of dependent claims with the subject matter of each other dependent claim or combinations of one or more features with other dependent claims or independent claims. Such combinations are proposed herein unless it is stated that a specific combination is not intended.

[0046] Any incorporation by reference of the above-mentioned documents is limited such that no subject matter is incorporated that is contrary to the explicit disclosure herein. Any incorporation by reference of the above-mentioned documents is further limited such that any claims contained in the documents are not incorporated herein by reference. Any incorporation by reference of the above-mentioned documents is further limited such that any definitions provided in the documents are not incorporated herein by reference unless expressly included herein.

[0047] For purposes of claim interpretation, it is expressly intended that the provisions of 35 USC § 112(f) will not be invoked unless the specific terms "means for" or "step for" are recited in a claim.

Claims

1. An electrosurgical device, the electrosurgical device being configured to harvest radio frequency (RF) energy, the electrosurgical device comprising: a distal portion, the distal portion comprising two electrodes; a proximal portion coupled to an electrical connector configured to provide a therapeutic RF signal and a continuous RF signal to an energy harvesting assembly housed within the electrosurgical device, the energy harvesting assembly comprising: a transformer configured to isolate and reduce the voltage of the therapeutic RF signal; AC-DC converter; and a DC-DC regulator configured to output a fixed voltage; and One or more loads are electrically coupled to the energy harvesting component and powered by the fixed voltage.

2. The electrosurgical device of claim 1, wherein the one or more loads are one or more of an LED, a sensor, a timer, a microprocessor, a memory, an RFID chip, a communication circuit system, and a battery.

3. The electrosurgical device of claim 1, wherein the one or more loads are configured to provide identification information about the electrosurgical device.

4. The electrosurgical device of claim 3, wherein the identification information comprises one or more of a model number, a serial number, and a number of operations in which the surgical instrument has been used.

5. The electrosurgical device of claim 1, wherein the AC-DC converter is a diode and capacitor circuit system.

6. The electrosurgical device of claim 1, wherein the therapy signal is between 200 KHz and 3.3 MHz.

7. An electrosurgical device according to claim 1, wherein the continuous signal is between 20 KHz and 300 KHz.

8. The electrosurgical device of claim 1, wherein the power of the fixed voltage is less than 10% of the therapeutic power.

9. The electrosurgical device of claim 1, further comprising an actuator, wherein the therapeutic RF signal is provided only when the actuator is actuated.

10. A method for supplying power to a load of an electrosurgical device, the method comprising: A radio frequency (RF) signal is provided to the electrosurgical device, and within the electrosurgical device: Isolating and reducing the RF signal to a range acceptable to the DC circuit system; converting the RF signal into a DC signal; adjusting the DC signal to a fixed value; and The DC signal is provided to the load at the fixed voltage.

11. The method of claim 10, wherein the load is an LED, a sensor, a timer, a microprocessor, a memory, an RFID chip, a communication circuit system, or a battery.

12. The method of claim 10, wherein the load is configured to provide identification information about the electrosurgical device.

13. The method of claim 12, wherein the identification information includes one or more of a model number, a serial number, and a number of operations in which the surgical instrument has been used.

14. The method of claim 10, wherein the RF signal is provided to the electrosurgical device between 200 KHz and 3.3 MHz.

15. The method of claim 10, wherein the RF signal is provided to the electrosurgical device between 20 KHz and 300 KHz.

16. The method of claim 10, wherein converting the RF signal is accomplished by diode and capacitor circuitry.

17. The method of claim 10, wherein reducing the RF signal is accomplished by a transformer.

18. The method of claim 10, wherein the fixed voltage is based on an acceptable tolerance of the electrosurgical device.

19. The method of claim 10, wherein the power of the fixed voltage is less than 10% of the therapeutic power.

20. An electrosurgical device configured to harvest radio frequency (RF) energy, the electrosurgical device comprising: an elongated distal portion comprising an active electrode and a return electrode; a proximal portion coupled to a three-pin electrical connector configured to provide a therapeutic RF signal and a continuous RF signal to an energy harvesting assembly housed within the electrosurgical device, the energy harvesting assembly comprising: a transformer configured to isolate and reduce the voltage of the therapy signal; AC-DC converters; a DC-DC regulator configured to output a fixed voltage; and A load is electrically coupled to the energy harvesting component and powered by the fixed voltage such that the load is isolated from voltage fluctuations in the therapeutic RF signal.

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