Surgical end effector assembly and surgical instrument for energy-based tissue cutting

Abstract

A surgical end effector assembly includes a first jaw member and a second jaw member configured to clamp tissue therebetween. The first jaw member includes a compression pad and the second jaw member includes a cutting electrode to enable tissue to be clamped between the cutting electrode and the compression pad. The compression pad is configured to facilitate cutting tissue sandwiched between the cutting electrode and the compression pad.

Description

[0001] Cross Reference to Related Applications This application claims the benefit of U.S. Provisional Patent Application Serial No. 63 / 462,693, filed April 28, 2023, the entire contents of which are incorporated herein by reference. TECHNICAL FIELD

[0002] The present disclosure relates to surgical instruments, and more particularly to surgical end effector assemblies and surgical instruments for energy-based tissue cutting, such as for surgical robotic systems. BACKGROUND

[0003] Surgical robotic systems are increasingly used in a variety of different surgical procedures. Some surgical robotic systems include a control console that supports a robotic arm. One or more different surgical instruments can be configured for use with the surgical robotic system and are selectively installable to the robotic arm. The robotic arm provides one or more inputs to the installed surgical instrument to enable operation of the installed surgical instrument.

[0004] Surgical forceps, an instrument that can be used with a robotic surgical system, rely on mechanical action between its jaw members to grasp, clamp, and constrict tissue. Electrosurgical forceps utilize controlled mechanical clamping action and energy to heat tissue to seal (or otherwise treat) tissue. Typically, once tissue is sealed, a cutting element is used to sever the tissue. Accordingly, many electrosurgical forceps are designed to incorporate a mechanical cutting element to effectively sever the sealed tissue (and / or to cut tissue independent of tissue sealing). Alternatively, surgical forceps can incorporate an energy-based (e.g., thermal, electrical, ultrasonic, etc.) cutting mechanism to cut tissue, whether the tissue is previously sealed or not. SUMMARY

[0005] As used herein, the term “distal” refers to the portion of the description that is further from an operator, whether a surgeon or a surgical robotic system, while the term “proximal” refers to the portion of the description that is closer to the operator. As utilized herein, terms including “generally,” “about,” “substantially,” and the like, mean to cover up to and including a variation of ±10% (e.g., manufacturing tolerances, material tolerances, usage tolerances, and environmental tolerances, measurement variations, design variations, and / or other variations). Within consistent ranges, any aspect described herein can be used in conjunction with any or all other aspects described herein.

[0006] According to aspects of the present disclosure, a surgical end effector assembly is provided that includes first and second jaw members having respective first and second tissue-contacting surfaces. At least one of the first or second jaw members is movable relative to the other between a spaced-apart position and an approximated position to clamp tissue between the first and second tissue-contacting surfaces. The second jaw member includes a cutting electrode extending therefrom toward the first jaw member. The first jaw member includes a compression pad configured to oppose the cutting electrode in the approximated position of the first and second jaw members to clamp tissue between the cutting electrode and the compression pad in the approximated position of the first and second jaw members. The compression pad includes a first portion having a first durometer and a second portion having a second durometer different from the first durometer.

[0007] In an aspect of the present disclosure, the first and second portions of the compression pad are vertically stacked such that the first portion is configured to contact tissue and the second portion is substantially unexposed within the first jaw member.

[0008] In another aspect of the present disclosure, the first and second portions of the compression pad are longitudinally aligned such that the first portion defines a compression pad proximal portion and the second portion defines a compression pad distal portion.

[0009] In yet another aspect of the present disclosure, the first and second portions of the compression pad are laterally aligned such that the first portion defines a compression pad right side portion and the second portion defines a compression pad left side portion.

[0010] In still another aspect of the present disclosure, the first portion of the compression pad includes a first outer segment and a second outer segment, and the second portion of the compression pad is disposed between the first and second outer segments.

[0011] In yet still another aspect of the present disclosure, the first portion includes a body of the compression pad, and the second portion includes a plurality of voids defined through the body of the compression pad. In such aspects, at least one void of the plurality of voids can be filled with a material different from a material forming the body of the compression pad.

[0012] In an aspect of the present disclosure, the first portion is a first overmold and the second portion is a second overmold.

[0013] In another aspect of the present disclosure, the second portion surrounds at least a portion of the first portion.

[0014] In yet another aspect of the present disclosure, the first portion includes a first filler material and the second portion includes a different second filler material or no filler material.

[0015] Another surgical end effector assembly provided in accordance with the present disclosure includes first and second jaw members having respective first and second tissue contact surfaces. At least one of the first or second jaw members is movable relative to the other of the first or second jaw members between a spaced-apart position and an approximated position to clamp tissue between the first and second tissue contact surfaces. The second jaw member includes a cutting electrode extending from the second jaw member toward the first jaw member. The first jaw member includes a compression pad disposed within a slot defined through the first tissue contact surface. The compression pad is configured to oppose the cutting electrode in the approximated position of the first and second jaw members to clamp tissue between the cutting electrode and the compression pad, the cutting electrode at least partially compressing the compression pad from an initial state to a compressed state in the approximated position of the first and second jaw members. In the initial state, a portion of the compression pad is spaced apart from a wall defining the slot. In the compressed state, the portion of the compression pad is urged toward and into contact with the wall defining the slot.

[0016] In an aspect of the disclosure, the slot includes at least one release recess. In such aspects, the wall defining the slot can be disposed within the release recess. Further, in aspects, the at least one recess can include a pair of release recesses disposed on either side of the compression pad.

[0017] In another aspect of the disclosure, the wall is a lateral wall of the slot.

[0018] In yet another aspect of the disclosure, the compression pad defines a volume that is less than a volume of the slot, such that in the initial state, a pocket is defined between the compression pad and the wall defining the slot.

[0019] A surgical instrument provided in accordance with the present disclosure includes a housing, a shaft assembly extending distally from the housing, and an end effector assembly extending distally from the shaft assembly. The end effector assembly includes first and second jaw members defining respective first and second tissue contact surfaces. At least one of the first or second jaw members is movable relative to the other of the first or second jaw members between a spaced-apart position and an approximated position to clamp tissue between the first and second tissue contact surfaces. The second jaw member includes a cutting electrode extending from the second jaw member toward the first jaw member. The first jaw member includes a compression pad configured to oppose the cutting electrode in the approximated position of the first and second jaw members to clamp tissue disposed between the cutting electrode and the compression pad in the approximated position of the first and second jaw members. The compression pad defines a varying compressibility in at least one dimension of the compression pad.

[0020] In one aspect of the disclosure, the compression pad includes portions formed of different materials, defining a varying compressibility.

[0021] In another aspect of the disclosure, the compression pad is disposed at least partially within a slot defined within the first jaw member. The slot defines a varying width, thereby varying the width of the compression pad and defining a varying compressibility.

[0022] In yet another aspect of the disclosure, the compression pad is disposed at least partially within a slot defined within the first jaw member. The varying compressibility is defined by a first portion of the compression pad extending into a previously unoccupied portion of the slot in response to compression of the compression pad and a second portion of the compression pad pushing against a wall of the slot in response to compression of the compression pad.

[0023] In yet another aspect of the disclosure, the varying compressibility at least partially corresponds to a variation in force applied to tissue clamped between the cutting electrode and the compression pad at a close position of the first jaw member and the second jaw member. BRIEF DESCRIPTION OF DRAWINGS

[0024] The above and other aspects and features of the present disclosure will become more apparent from the following detailed description, taken in conjunction with the accompanying drawings, in which like reference characters refer to like or similar elements throughout.

[0025] FIG. 1 is a schematic view of a surgical robotic system in accordance with aspects of the present disclosure, including a control tower, a console, and one or more surgical robotic arms; FIG. 2 is a perspective view of a surgical robotic arm of the surgical robotic system in accordance with aspects of the present disclosure; FIG. 1 FIG. 3 is a perspective view of a setup arm in accordance with aspects of the present disclosure, having FIG. 1 a surgical robotic arm of the surgical robotic system in accordance with aspects of the present disclosure; FIG. 4 is a schematic view of a computer architecture of the surgical robotic system in accordance with aspects of the present disclosure; FIG. 1 FIG. 5 is a perspective view of a surgical instrument provided in accordance with aspects of the present disclosure, configured for mounting on a robotic arm of a surgical robotic system such as FIG. 1 the surgical robotic system in accordance with aspects of the present disclosure; FIG. 6A and FIG. 6B are, respectively, FIG. 5 front and rear perspective views of a proximal portion of the surgical instrument, with the housing removed; ​​FIG. 7 is a front perspective view of a proximal portion of the surgical instrument with the outer housing and additional internal components removed; FIG. 5 FIG. 8A and FIG. 8B is a side view of a portion of the end effector assembly of the surgical instrument with the jaw members of the end effector assembly disposed in a spaced apart position and a close position, respectively; FIG. 5 FIG. 9 is a transverse cross-sectional view of the end effector assembly of the surgical instrument; FIG. 5 FIG. 10A is a plan view of one of the jaw members of the end effector assembly of the surgical instrument; FIG. 5 FIG. 10B is a plan view of another jaw member of the end effector assembly of the surgical instrument; FIG. 5 is a perspective view of various different configurations of compression pads according to aspects of the present disclosure and configured for use with the end effector assembly of the surgical instrument of FIG. 11 to FIG. 19 FIG. 5 is a transverse cross-sectional view of one of the jaw members of the end effector assembly of the surgical instrument according to aspects of the present disclosure, the jaw member including various different configurations of compression pads disposed therein; and FIG. 20 to FIG. 29 is a side view of another compression pad according to aspects of the present disclosure for use with the end effector assembly of the surgical instrument of FIG. 5 FIG. 30 FIG. 5 DETAILED DESCRIPTION

[0026] ​​​​​​​​The present disclosure provides surgical end effector assemblies and surgical instruments for energy-based tissue cutting. As described in detail below, the surgical end effector assemblies and surgical instruments of the present disclosure are configured for use with a surgical robotic system, which can include, for example, a surgical console, a control tower, and one or more movable carts having surgical robotic arms coupled to mounting arms. The surgical console receives user input through one or more interface devices, which is interpreted by the control tower as movement commands for moving the surgical robotic arms. The surgical robotic arms include a controller configured to process the movement commands and generate torque commands for actuating one or more actuators of the robotic arms, which in turn move the robotic arms in response to the movement commands. Those skilled in the art will appreciate that, although described in connection with a surgical robotic system, the present disclosure can also be adapted for use with handheld surgical instruments, such as endoscopic surgical instruments and / or open surgical instruments, whether manually operated or motorized.

[0027] Reference FIG. 1 The surgical robotic system 10 includes a control tower 20 that is connected to components of the surgical robotic system 10, including a surgical console 30 and one or more robotic arms 40. Each robotic arm 40 includes a surgical instrument 50, 51 removably coupled thereto. Each robotic arm 40 is also coupled to a movable cart 60.

[0028] One or more of the surgical instruments 50, 51 can be configured for use during minimally invasive surgery and / or open surgery. In aspects, one of the surgical instruments 50 can be an endoscope configured to provide a video feed for a clinician, such as an endoscopic camera 51. In aspects, one of the surgical instruments 50 can be an energy-based surgical instrument, such as an energy-based forceps configured to seal tissue by clamping the tissue between opposing structures and applying energy (e.g., electrical, thermal, ultrasonic, optical, etc. energy) thereto and to cut tissue by applying energy (e.g., electrical, thermal, ultrasonic, optical, etc. energy) thereto. An example of such an energy-based surgical forceps for energy-based sealing and cutting is described in detail below and identified by reference numeral 110. FIG. 5

[0029] The endoscopic camera 51 is configured to capture video of a surgical site. The surgical console 30 includes a first display 32 that displays a video feed of the surgical site provided by the endoscopic camera 51 and a second display 34 that displays a user interface for controlling the surgical robotic system 10. The first and second displays 32, 34 are touchscreens that allow for display and interaction with various graphical user inputs.

[0030] ​The surgical console 30 also includes a plurality of user interface devices, such as a foot pedal 36 and a pair of hand controller 38a and 38b, which are used by the user to remotely control the robotic arm 40. The surgical console further includes an armrest 33 for supporting the clinician’s arms while operating the hand controllers 38a and 38b.

[0031] The control tower 20 includes a display 23 (which can be a touch screen) and outputs on a graphical user interface (GUI). The control tower 20 also serves as an interface between the surgical console 30 and the one or more robotic arms 40. In particular, the control tower 20 is configured to control the robotic arms 40, such as to move the robotic arms 40 and corresponding surgical instruments 50, 51 based on a set of programmable instructions and / or input commands from the surgical console 30 in such a way that the robotic arms 40 and surgical instruments 50, 51 perform a desired sequence of movements in response to input from the foot pedal 36 and / or hand controllers 38a and 38b.

[0032] Each of the control tower 20, the surgical console 30, and the robotic arms 40 includes a respective computer 21, 31, 41. The computers 21, 31, 41 are interconnected to each other by using any suitable communication network based on wired or wireless communication protocols. As used herein, the term “network,” whether plural or singular, means a data network, including but not limited to the Internet, an intranet, a wide area network, or a local area network, and is not limited to the full scope of the definition of communication networks encompassed by the present disclosure. Suitable protocols include, but are not limited to, Transmission Control Protocol / Internet Protocol (TCP / IP), User Datagram Protocol / Internet Protocol (UDP / IP), and / or Datagram Congestion Control Protocol (DCCP). Wireless communication can be achieved through one or more wireless configurations, such as radio frequency, light, Wi-Fi, Bluetooth® (an open wireless protocol used to exchange data over short distances from fixed and mobile devices, creating personal area networks (PANs), using short length radio waves), ZigBee® (a specification for a suite of high-level communication protocols using small, low-power digital radios based on the IEEE 122.15.4-2003 wireless personal area network (WPAN) standard).

[0033] The computers 21, 31, 41 can include any suitable processor (not shown) operatively connected to memory (not shown), which can include one or more of volatile, non-volatile, magnetic, optical, or electrical media, such as read-only memory (ROM), random-access memory (RAM), electrically-erasable programmable ROM (EEPROM), non-volatile RAM (NVRAM), or flash memory. The processor can be any suitable processor adapted to perform the operations, calculations, and / or instruction sets described in the present disclosure (e.g., control circuitry), including, but not limited to, a hardware processor, a field-programmable gate array (FPGA), a digital signal processor (DSP), a central processing unit (CPU), a microprocessor, and combinations thereof. Those skilled in the art will understand that the processor can be replaced by any logic processor (e.g., control circuitry) adapted to perform the algorithms, calculations, and / or instruction sets described herein.

[0034] With reference to FIG. 2 and FIG. 3 Each robotic arm 40 can include a plurality of links 42a, 42b, 42c interconnected at joints 44a, 44b, 44c, respectively. The joint 44a is configured to secure the robotic arm 40 to a movable cart 60 and defines a first longitudinal axis. The movable cart 60 includes a lift 61 and a mounting arm 62 that provides a base for the installation of the robotic arm 40. The lift 61 allows the mounting arm 62 to move vertically. The movable cart 60 also includes a display 69 for displaying information about the robotic arm 40.

[0035] The mounting arm 62 includes a first link 62a, a second link 62b, and a third link 62c that provide lateral steerability of the robotic arm 40. The links 62a, 62b, 62c are interconnected at joints 63a and 63b, each of which can include an actuator (not shown) for rotating the links 62a and 62b relative to each other and to the link 62c. In particular, the links 62a, 62b, 62c are movable in their respective lateral planes that are parallel to each other, thereby allowing the robotic arm 40 to extend relative to a patient (e.g., a surgical table). In aspects, the robotic arm 40 can be coupled to a surgical table (not shown). The mounting arm 62 includes a control device 65 for adjusting the movement of the links 62a, 62b, 62c and the lift 61.

[0036] The third link 62c includes a rotatable base 64 having two degrees of freedom. In particular, the rotatable base 64 includes a first actuator 64a and a second actuator 64b. The first actuator 64a is rotatable about a first fixed arm axis that is perpendicular to a plane defined by the third link 62c, and the second actuator 64b is rotatable about a second fixed arm axis that is transverse to the first fixed arm axis. The first and second actuators 64a, 64b allow for full three-dimensional orientation of the robotic arm 40.

[0037] Referring also to FIG. 1 and FIG. 2 The robotic arm 40 also includes a holder 46 that defines a second longitudinal axis and is configured to receive the IDU 52. The IDU 52 is configured to couple to actuation mechanisms of the surgical instrument 50 and the endoscope camera 51 and to move (e.g., rotate) and actuate the instrument 50 and / or the endoscope camera 51. The IDU 52 transmits actuation forces from its actuators to the surgical instrument 50 and / or the endoscope camera 51 to actuate components of the surgical instrument 50 (e.g., an end effector). The holder 46 includes a sliding mechanism 46a that is configured to move the IDU 52 along the second longitudinal axis defined by the holder 46. The holder 46 also includes a joint 46b that rotates the holder 46 relative to the link 42c.

[0038] The robotic arm 40 further includes a plurality of manual override buttons 53 disposed on the IDU 52 and / or the mounting arm 62 and that can be used in a manual mode. A clinician can press one of the buttons 53 to move a component associated with that button 53.

[0039] The joints 44a and 44b include actuators 48a and 48b that are configured to drive the joints 44a, 44b, 44c relative to each other through a series of belts 45a and 45b or other mechanical linkages (such as drive rods, cables, or levers, etc.). In particular, the actuator 48a is configured to rotate the robotic arm 40 about a longitudinal axis defined by the link 42a.

[0040] Actuator 48b of joint 44b is coupled to joint 44c via belt 45a, and joint 44c is in turn coupled to joint 46c via belt 45b. Joint 44c can include a transfer case that couples belts 45a and 45b, such that actuator 48b is configured to rotate each of links 42b, 42c and holder 46 relative to one another. More specifically, links 42b, 42c and holder 46 are passively coupled to actuator 48b, which is forced to rotate about a remote center point "P" that is located at the intersection of the first axis defined by link 42a and the second axis defined by holder 46. As such, actuator 48b controls the angle "A" between the first and second axes, thereby allowing for the orientation of surgical instrument 50 to be controlled. Since links 42a, 42b, 42c and holder 46 are interconnected via belts 45a and 45b, the angles between links 42a, 42b, 42c and holder 46 are also adjusted to achieve the desired angle "A". In aspects, some or all of joints 44a, 44b, 44c can include actuators to obviate the need for a mechanical linkage.

[0041] With reference to FIG. 1 and FIG. 4 Each of the computers 21, 31, 41 of the surgical robot system 10 can include multiple controllers, which can be implemented in hardware and / or software. The computer 21 of the control tower 20 includes a controller 21a and a safety observer 21b. The controller 21a receives data from the computer 31 of the surgical console 30 regarding the current positions and / or orientations of the handle controllers 38a and 38b and the states of the foot pedals 36 and other buttons. The controller 21a processes these input positions to determine the desired drive commands for each joint of the robotic arm 40 and / or the IDU 52 and transmits these desired drive commands to the computer 41 of the robotic arm 40. The controller 21a also receives back the actual angles of the joints and uses this information to determine force feedback commands, which are transmitted back to the computer 31 of the surgical console 30 to provide haptic feedback through the handle controllers 38a and 38b. The handle controllers 38a and 38b include one or more haptic feedback vibratory devices that output haptic feedback. The safety observer 21b performs validity checks on the data going into and out of the controller 21a, and if an error in data transmission is detected, notifies a system fault handler to place the computer 21 and / or the surgical robot system 10 in a safe state.

[0042] The computer 41 includes multiple controllers, namely, a cart master controller 41a, a setup arm controller 41b, a robotic arm controller 41c, and an IDU controller 41d. The cart master controller 41a receives and processes joint commands from the controller 21a of the computer 21 and transmits them to the setup arm controller 41b, the robotic arm controller 41c, and the IDU controller 41d. The cart master controller 41a also manages instrument exchange and the overall state of the movable cart 60, the robotic arm 40, and the IDU 52. The cart master controller 41a also transmits actual joint angles back to the controller 21a.

[0043] With additional reference to FIG. 2 and FIG. 3 The setup arm controller 41b controls each of the joints 63a and 63b, as well as the rotatable base 64 of the setup arm 62, and computes the required motor movement commands (e.g., motor torque) for the pitch axis and controls the brakes. The robotic arm controller 41c controls each joint 44a and 44b of the robotic arm 40 and computes the desired motor torque required for gravity compensation, friction compensation, and closed loop position control of the robotic arm 40. The robotic arm controller 41c computes movement commands based on the computed torque. The computed motor commands are then transmitted to one or more of the actuators 48a and 48b in the robotic arm 40. Actual joint positions are then transmitted back to the robotic arm controller 41c by the actuators 48a and 48b.

[0044] The IDU controller 41d receives desired joint angles (such as wrist angles and jaw angles) for the surgical instrument 50 and computes the desired current for the motors in the IDU 52. The IDU controller 41d computes actual angles based on motor positions and transmits these actual angles back to the cart master controller 41a.

[0045] The control of the robotic arm 40 is as follows. First, the pose of the handle controller (e.g., handle controller 38a) controlling the robotic arm 40 is transformed to the desired pose of the robotic arm 40 by a hand-eye transform function executed by the controller 21a. The hand-eye function, as well as other functions described herein, are implemented in software executable by the controller 21a or any other suitable controller described herein. The pose of the handle controller 38a can be implemented as a coordinate position and roll-pitch-yaw (“RPY”) orientation relative to a coordinate frame fixed to the surgical console 30. The desired pose of the instrument 50 is relative to a fixed frame on the robotic arm 40. The pose of the handle controller 38a is then scaled by a scaling function executed by the controller 21a. In aspects, by the scaling function, the coordinate position is scaled down, and the orientation is scaled up. Additionally, the controller 21a also executes a clutch function, which disengages the handle controller 38a from the robotic arm 40. In particular, if certain movement limits or other boundaries are exceeded, the controller 21a stops transmitting movement commands from the handle controller 38a to the robotic arm 40 and essentially acts as a virtual clutch mechanism, for example, limiting the mechanical input from affecting the mechanical output.

[0046] The desired pose of the robotic arm 40 is based on the pose of the handle controller 38a, which is then passed through an inverse kinematics function executed by the controller 21a. The inverse kinematics function calculates the angles of the joints 44a, 44b, 44c of the robotic arm 40 that achieve the scaled and adjusted pose input by the handle controller 38a. The calculated angles are then passed to the robotic arm controller 41c, which includes joint axis controllers with proportional-derivative (“PD”) controllers, a friction estimator module, a gravity compensator module, and a double-sided saturation block configured to limit the commanded torques of the motors of the joints 44a, 44b, 44c.

[0047] Turning to FIG. 5 to FIG. 7 , the surgical instrument 110 provided in accordance with the present disclosure generally includes a housing 120, a shaft 130 extending distally from the housing 120, an end effector assembly 140 extending distally from the shaft 130, and an actuation assembly 1100 disposed within the housing 120 and operatively associated with the end effector assembly 140. The instrument 110 is detailed herein as an articulating electrosurgical forceps configured for use with a surgical robotic system, such as the surgical robotic system 10 (shown in FIG. 1) provided in accordance with the present disclosure. However, aspects and features of the instrument 110 provided in accordance with the present disclosure detailed below are equally applicable for use with other suitable surgical instruments (e.g., graspers, staplers, clip appliers) and / or for use in other suitable surgical systems (e.g., motorized systems, other power-driven systems, and / or manually actuated surgical systems, including handheld instruments). FIG. 1 ​

[0048] With specific reference FIG. 5 , the housing 120 of the instrument 110 includes first and second housing portions 122a, 122b, and a proximal faceplate 124 that cooperate to enclose the actuation assembly 1100 therein. The proximal faceplate 124 includes through-holes defined therein through which the input couplings 1110-1140 of the actuation assembly 1100 extend. FIG. 6B A pair of latching levers 126 (only one of which is illustrated in FIG. 5 ) extending outwardly from opposite sides of the housing 120 enable the housing 120 to be releasably engaged with a robotic arm 40 (e.g., of the surgical robotic system 10 (e.g., of the surgical robotic system 10 FIG. 1 ) of a surgical robotic system (e.g., the surgical robotic system 10 (e.g., the surgical robotic system 10 FIG. 1 ) of a surgical robotic system (e.g., the surgical robotic system 10 (e.g., the surgical robotic system 10

[0049] With further reference FIG. 6A to FIG. 7 , a plurality of electrical contacts 190 extend through one or more apertures defined by the proximal faceplate 124 to enable electrical communication between the instrument 110 and a surgical robotic system 10 (e.g., the surgical robotic system 10 FIG. 1 ) when the instrument 110 is engaged on a robotic arm thereof, e.g., to enable communication of data, control, and / or power signals therebetween. As an alternative to the electrical contacts 190 extending through the proximal faceplate 124, other suitable transmitter, receiver, and / or transceiver components capable of enabling communication of data, control, and / or power signals are also contemplated, e.g., through the use of RFID, Bluetooth®, WiFi®, or via any other suitable wired, wireless, contact-based, or non-contact-based communication method. At least some of the electrical contacts 190 are electrically coupled with electronics 192 mounted on the inside of the proximal faceplate 124, e.g., within the housing 120. The electronics 192 can include, e.g., a storage device, a communication device (including suitable input / output components), and a CPU comprising a memory and a processor. The electronics 192 can be mounted on a circuit board or otherwise configured, e.g., as a chip.

[0050] The storage device of the electronics 192 stores information related to the surgical instrument, such as: a part number, e.g., a SKU number; a date of manufacture; a location of manufacture, e.g., a location code; a serial number; a lot number; usage information; setup information; adjustment information; calibration information; security information such as an encryption key, and / or other suitable additional or alternative data. The storage device of the electronics 192 can be, e.g., a magnetic disk, a flash memory, an optical disk, or other suitable data storage device.

[0051] Instead of or in addition to storing the above information in a storage device of the electronics 192, some or all of such information (e.g., usage information, calibration information, setup information, and / or adjustment information) can be stored in a storage device associated with the surgical robotic system 10 ( FIG. 1 ), a remote server, a cloud server, etc., and accessible via the instrument 110 and / or the surgical robotic system 10 ( FIG. 1 ). In such configurations, the information can be updated, e.g., through manufacturer-provided updates, and / or can be applied to individual instruments, instrument units (e.g., units from the same manufacturing site, manufacturing cycle, batch number, etc.), or to all instruments. Still further, even where the information is stored locally on each instrument, the information can be manually or automatically updated through manufacturer-provided updates upon connection to the surgical robotic system 10 ( FIG. 1 ).

[0052] Referring again to FIG. 5 , the shaft 130 of the instrument 110 accordingly includes a distal clevis segment 132, a proximal segment 134, and an articulation segment 136 disposed between the distal clevis segment 132 and the proximal segment 134. The articulation segment 136 includes one or more articulation components 137, such as links, joints, etc. A plurality of articulation motion cables 138 (e.g., four (4) articulation motion cables) or other suitable actuators extend through the articulation segment 136. More specifically, the articulation motion cables 138 are operably coupled at their distal ends to the distal clevis segment 132 of the shaft 130 and extend proximally from the distal clevis segment 132 of the shaft 130, through the articulation segment 136 of the shaft 130 and the proximal segment 134 of the shaft 130, and into the housing 120, where the articulation motion cables 138 are operably coupled with an articulation motion subassembly 1200 of the actuation assembly 1100 ( FIG. 6A ) to effect selective articulation motion of the distal clevis segment 132 (and thus the end effector assembly 140) relative to the proximal segment 134 and the housing 120, e.g., about at least two axes of articulation motion (e.g., yaw and pitch articulation motion). The articulation motion cables 138 are arranged in a generally rectangular configuration, although other suitable configurations are also contemplated. In some configurations, as an alternative, the shaft 130 is substantially rigid, malleable, or flexible and is not configured for active articulation motion. The articulation motion subassembly 1200 is described in greater detail below.

[0053] With respect to articulation motion of the end effector assembly 140 relative to the proximal segment 134 of the shaft 130, actuation of the articulation motion cables 138 can be done in pairs. More particularly, to pitch the end effector assembly 140, the upper cable pairs 138 are actuated in a similar manner, while the lower cable pairs 138 are actuated in a similar but opposite manner relative to one another but opposite relative to the upper cable pairs 138. With respect to yaw articulation motion, the right cable pairs 138 are actuated in a similar manner, while the left cable pairs 138 are actuated in a similar but opposite manner relative to one another but opposite relative to the right cable pairs 138. Other configurations of articulation motion cables 138 or other articulation motion actuators are also contemplated.

[0054] With continued reference to FIG. 5 , the end effector assembly 140 accordingly includes a first jaw member 142 and a second jaw member 144. Each jaw member 142, 144 accordingly includes a proximal flange 143a, 145a and a distal body 143b, 145b. The distal body 143b, 145b defines opposing tissue contact surfaces 146, 148, respectively. The proximal flanges 143a, 145a are pivotably coupled to one another about a pivot axis 150 and operably coupled to one another via a cam slot assembly 152 including a cam pin slidably received within a cam slot defined within the proximal flange 143a, 145a of at least one of the jaw members 142, 144 to enable the jaw members 142 to pivot relative to the jaw member 144 and the distal segment 132 of the shaft 130 between a spaced apart position (e.g., an open position of the end effector assembly 140) and an approximated position (e.g., a closed position of the end effector assembly 140) to clamp tissue between the tissue contact surfaces 146, 148. As an alternative to this single-sided configuration, a double-sided configuration can be provided in which both jaw members 142, 144 are pivotable relative to one another and relative to the distal segment 132 of the shaft 130. Alternatively, the above detailed configuration can be reversed, e.g., in which the jaw member 142 is a fixed jaw member and the jaw member 144 is movable relative to the jaw member 142. Other suitable jaw actuation mechanisms for double-sided and / or single-sided jaw configurations are also contemplated.

[0055] In some configurations, the jaw member 144 supports a longitudinally extending cutting electrode 149 in a slot 160 defined through the tissue contact surface 148 and a portion of the distal body 145b of the jaw member 144, while the jaw member 142 includes a compression pad 162 disposed in a slot 161 defined through the tissue contact surface 146 and a portion of the distal body 143b of the jaw member 142. FIG. 9 FIG. 8A to FIG. 9 In such aspects, in the approximated position of the jaw members 142, 144, the cutting electrode 149 is urged into contact with the compression pad 162​FIG. 8A to FIG. 9 ) to clamp (and in aspects, tension) tissue therebetween. The cutting electrode 149 can then be energized to cut tissue disposed between the cutting electrode 149 and the compression pad 162 (and vice versa). The cutting electrode 149 can additionally or alternatively be used to cut tissue in the jaw-opened configuration, e.g., with the jaw members 142, 144 disposed in the spaced-apart position. The cutting electrode 149 can be configured to be energized with monopolar radiofrequency (RF) energy from a surgical generator (not shown) to conduct RF energy to tissue to cut tissue, with the RF energy being returned to the generator via a remote return device (such as a return pad (not shown)) or a local return device (such as another portion of the end effector assembly 140) or a separate instrument (not shown) (e.g., a hook, probe, etc.) to complete the circuit. Alternatively or additionally, the cutting electrode 149 can be energized with bipolar RF energy, with the energy conducted from the cutting electrode 149 to tissue being returned via either or both of the tissue-contacting surfaces 146, 148 of the jaw members 142, 144 or other suitable local return device, respectively. FIG. 8A to FIG. 9

[0056] Still referring to FIG. 5 , the drive rod 1484 is operably coupled to the cam slot assembly 152 of the end effector assembly 140, e.g., in cam pin engagement therewith, such that longitudinal actuation of the drive rod 1484 causes the jaw member 142 to pivot relative to the jaw member 144 between the spaced-apart position and the close position. More specifically, proximal pushing of the drive rod 1484 causes the jaw member 142 to pivot relative to the jaw member 144 toward the close position, while distal pushing of the drive rod 1484 causes the jaw member 142 to pivot relative to the jaw member 144 toward the spaced-apart position. However, other suitable mechanisms and / or configurations for causing the jaw member 142 to pivot relative to the jaw member 144 between the spaced-apart position and the close position in response to selective actuation of the drive tube 1484 are also envisioned. The drive rod 1484 extends proximally from the end effector assembly 140 through the shaft 130 and into the housing 120, where it is operably coupled with the jaw drive subassembly 1400 of the actuation assembly 1100 (and FIG. 6A and FIG. 6B ) to enable the end effector assembly 140 to be selectively actuated to clamp tissue therebetween and to apply a clamping force within an appropriate clamping force range.

[0057] ​The tissue-contacting surfaces 146, 148 of the jaw members 142, 144 are formed at least partially of electrically-conductive material, respectively, and can be energized to different electrical potentials to enable RF electrical energy to be conducted through tissue clamped therebetween, although the tissue-contacting surfaces 146, 148 can alternatively be configured to supply any suitable energy (e.g., thermal, microwave, optical, ultrasonic, etc.) through tissue clamped therebetween for energy-based tissue treatment. The instrument 110 defines a conductive pathway (not shown) through the housing 120 and shaft 130 to the end effector assembly 140 that can include leads, contacts, and / or conductive components to enable the tissue-contacting surfaces 146, 148 of the jaw members 142, 144 to be electrically connected to an energy source (not shown), such as an electrosurgical generator, for supplying energy to the tissue-contacting surfaces 146, 148 to treat (e.g., seal) tissue clamped therebetween.

[0058] Further reference is made to FIG. 6A to FIG. 7 As noted above, the actuation assembly 1100 is disposed within the housing 120 and includes an articulation motion subassembly 1200 and a jaw drive subassembly 1400. The articulation motion subassembly 1200 is operably coupled between the first and second input couplings 1110, 1120 of the actuation assembly 1100 and the articulation motion cable 138 (FIG. 1), respectively, such that upon receipt of appropriate input in the first and / or second input couplings 1110, 1120, the articulation motion subassembly 1200 manipulates the cable 138 (FIG. 1) to articulate the end effector assembly 140 in a desired direction, such as to pitch and / or yaw the end effector assembly 140. The articulation motion subassembly 1200 is described in greater detail below. FIG. 5 ) in response to appropriate input received in the first and / or second input couplings 1110, 1120. FIG. 5 ) in response to appropriate input received in the first and / or second input couplings 1110, 1120.

[0059] The jaw drive subassembly 1400 is operably coupled between the fourth input coupling 1140 of the actuation assembly 1100 and the drive rod 1484 such that upon receipt of appropriate input in the fourth input coupling 1140, the jaw drive subassembly 1400 pivots the jaw members 142, 144 between the spaced-apart and approximated positions to clamp tissue therebetween and apply a clamping force within an appropriate jaw force range.

[0060] The actuation assembly 1100 is configured to operably interface with a surgical robotic system, such as the system 10 (FIG. 1), when the instrument 110 is mounted on a robotic arm of the surgical robotic system to enable robotic operation of the actuation assembly 1100 to provide the functionality detailed above. That is, the surgical robotic system 10 (FIG. 1) is configured to receive input from a user to control the instrument 110 and to provide appropriate input to the actuation assembly 1100 to enable the functionality detailed above. FIG. 1 FIG. 1 ​) selectively provide input, such as rotational input, to the input couplings 1110-1140 of the actuation assembly 1100 to articulate the end effector assembly 140, clamp tissue between the jaw members 142, 144, and / or cut tissue clamped between the jaw members 142, 144. However, as noted above, it is also contemplated that the actuation assembly 1100 is configured to interface with any other suitable surgical system, such as a manual surgical handle, a powered surgical handle, etc.

[0061] Turning to FIG. 8A to FIG. 10B , a distal portion of the end effector assembly 140 is shown with the jaw members 142, 144 disposed in a spaced-apart position (FIG. 20A) FIG. 8A ) and a close position (FIG. 20B) FIG. 8B and FIG. 9 . In aspects, either or both of the tissue-contacting surfaces 146, 148 of the jaw members 142, 144 are defined by respective tissue-contacting pads 166, 168 disposed on opposite surfaces of the distal bodies 143b, 145b of the jaw members 142, 144, respectively. As detailed above, the jaw member 144 supports the cutting electrode 149 in a slot 160 defined through the tissue-contacting surface 148 (and through the tissue-contacting pad 168 and a portion of the distal body 145b of the jaw member 144), while the jaw member 142 includes a compression pad 162 disposed in a slot 161 defined through the tissue-contacting surface 146 (and through the tissue-contacting pad 166 and a portion of the distal body 143b of the jaw member 142) and configured to oppose the cutting electrode 149 in the close position (FIG. 20B) FIG. 8B and FIG. 9 ) of the jaw members 142, 144. The tissue-contacting surfaces 146, 148 can define a substantially U-shaped configuration, wherein the slots 161, 160 defined therethrough terminate at locations spaced proximally from the distal ends of the tissue-contacting surfaces 146, 148 (see FIG. 10A and FIG. 10B ).

[0062] The cutting electrode 149 protrudes from the jaw member 144 beyond the tissue-contacting pad 168 and toward the jaw member 142. The compression pad 162 can be substantially flush with the tissue-contacting surface 146 of the tissue-contacting pad 166, can be recessed relative to the tissue-contacting surface, or can protrude from the tissue-contacting surface 146 of the tissue-contacting pad 166 toward the jaw member 144. The compression pad 162 and the jaw member 142 in combination with the cutting electrode 149 are configured such that in the close position (see FIG. 8B and FIG. 9), the cutting electrode 149 is urged into the compression pad 162 and at least partially compresses the compression pad (with tissue clamped therebetween), facilitating electrical tissue cutting when the cutting electrode 149 is activated. Contact between the cutting electrode 149 and the compression pad 162 can also maintain spacing between the tissue contact surfaces 146, 148 to inhibit electrical shorting via contact therebetween.

[0063] Either or both of the jaw members 142, 144 can include a structural jaw support 172, 174 that defines the respective proximal flange 143a, 145a of the jaw member 142, 144 and extends into the respective distal body 143b, 145b. In such configurations, the distal body 143b, 145b of either or both of the jaw members 142, 144 can further include a jaw housing 173, 175 that surrounds the structural jaw support 172, 174 and supports the tissue contact plate 166, 168 thereon, respectively. The jaw housing 173, 175 can be formed from an insulative material and, in aspects, can be overmolded around the jaw support 172, 174 and a portion of the tissue contact plate 166, 168 to form the jaw member 142, 144 and secure its components to one another. In other configurations, the jaw housing 173, 175 is electrically conductive and is electrically isolated from other components of the jaw member 142, 144 via suitable insulation. Alternatively or additionally, either or both of the jaw members 142, 144 can be formed from a unitary conductive material that defines its structural jaw support, tissue contact surface, and jaw housing. In such configurations, at least a portion of the jaw housing can be coated with an insulative material. Further, with respect to configurations in which the jaw member 144 is formed from a unitary material, the cutting electrode 149 can be electrically isolated from the remainder of the jaw member, e.g., via an insulator disposed therebetween. Accordingly, as used herein, reference to a jaw housing 173, 175 includes an insulative jaw housing, a conductive jaw housing, and / or a unitary jaw structure that defines the jaw housing. Further, the two jaw members 142, 144 can be similarly configured or can define different configurations, such as any combination of the jaw configurations detailed herein.

[0064] Turning to FIG. 11 to FIG. 30 , in conjunction with FIGS. 8 to FIG. 10BAs described above, the compression pad 162 and the gripper members 142 are configured to facilitate electro-cutting of tissue held between the gripper members 142, 144 when the cutting electrode 149 is activated. More specifically, the compression pad 162 is at least partially elastically compressible and defines a suitable hardness, a suitable hardness profile (e.g., portions with different hardness), a suitable size and shape configuration, and / or a suitable configuration relative to the gripper members 142 (and the gripper members 142 may combine with the compression pad 162 to define a suitable configuration) to facilitate holding the tissue between the compression pad 162 and the cutting electrode 149 with sufficient force (and in various respects, suitable tension), thereby enabling efficient and effective electro-cutting of the tissue when the cutting electrode 149 is activated. (Refer to below) FIG. 11 to FIG. 30 Various aspects and features of the compression pad 162 and / or gripper member 142 are detailed to enable such effective and efficient electro-cutting of tissue when the cutting electrode 149 is activated. To a consistent degree, any or all of these aspects and features may be used in any or all of the other aspects and features in any suitable combination. Furthermore, although some of the compression pads detailed below are shown as isolated and not disposed within the gripper member 142 to better demonstrate their features, it should be understood that these compression pads are configured for positioning within the gripper member 142 in any manner detailed herein. Furthermore, the orientation terms referenced with respect to these compression pads (e.g., proximal, distal, upper, lower, etc.) correspond to the same orientation of the gripper member 142.

[0065] like FIG. 10B As shown, the width of the compression pad 162 may taper along at least a portion of its length in a direction from the proximal to the distal side of the gripper member 142. This width taper of the compression pad 162 may correspond to a similar width taper of the gripper member 142. Alternatively, the width of the compression pad 162 may taper differently from the width taper of the gripper member 142, or it may taper in width without tapering in width. In all respects, the width taper of the compression pad 162 may be uniform, non-uniform, continuous, stepped, random, or provided in any other suitable manner. Similarly, the width of the slot 161 may taper with the width of the compression pad 162, or it may taper differently from (or not taper at all) the width of the compression pad 162.

[0066] Regardless of the specific configuration of the tapered compression pad 162, the tapering of the compression pad 162 facilitates the clamping of the compression pad 162 with the cutting electrode 149. FIG. 9 Apply substantially uniform or more uniform pressure to the tissue between the compression pad 162 and the cutting electrode 149. More specifically, this applies pressure to the tissue between the compression pad 162 and the cutting electrode 149. FIG. 9The force on the tissue between the compression pad 162 and the cutting electrode 149 decreases with increasing distance from the pivot (e.g., pivot 150), and the force applied towards the proximal end of the compression pad 162 is greater than the force applied towards the distal end of the compression pad 162. To at least partially offset this decrease in the force applied in the proximal-to-distal direction, the width of the compression pad 162 gradually decreases, reducing the exposed surface area of ​​the compression pad 162 along the gripper member 142 in the proximal-to-distal direction. Therefore, although the applied force decreases in the proximal-to-distal direction, the surface area also decreases in the proximal-to-distal direction, resulting in a decrease in the force applied to the tissue between the compression pad 162 and the cutting electrode 149. FIG. 9 The pressure on the tissue between the gripper members 142 (defined as the force per unit surface area) is substantially uniform or more uniform along the length of the gripper member 142. In other respects, the width of the compression pad 162 does not taper or define other suitable tapered portions.

[0067] refer to FIG. 11 This shows a configuration for use with gripper member 142 ( FIG. 8A to FIG. 9 and FIG. 10B A compression pad used in conjunction with any other suitable gripper member, the compression pad being identified by reference numeral 1162. Although the compression pad 1162 is shown as defining a rectangular prism configuration, the compression pad 1162 may define any other suitable shape configuration, such as, but not limited to, those detailed herein.

[0068] Compression pad 1162 is substantially uniform in shape and / or material (multiple materials) along its length, width across its width, and / or depth through its depth, such that it exhibits substantially similar properties (e.g., stiffness) in these dimensions (multiple dimensions). Compression pad 1162 may be substantially solid, for example, without or without openings through it, and may be formed of any suitable material, such as silicone or polytetrafluoroethylene (PTFE). Other suitable resilient compressible materials with sufficient thermal properties are also contemplated for forming at least a portion of compression pad 1162, such as resilient compressible materials capable of withstanding temperatures of at least 200ºC in each respect; in other respects, at least 240ºC; or in other respects, at least 260ºC. In each respect, compression pad 1162 is formed of one or more overmolded or injection-molded materials.

[0069] In aspects, the compression pad 1162 can be formed of a single material or a substantially uniform mixture of materials. Alternatively or additionally, the compression pad can include filler material disposed thereon (e.g., on its tissue-contacting surface) or therein (e.g., distributed uniformly or non-uniformly throughout the compression pad 1162). Such filler materials include, but are not limited to: calcium carbonate, talc, silica, wollastonite, clay, calcium sulfate fibers, mica, glass beads, and alumina trihydrate. Filler materials such as those described above provide texture and / or roughness that increases gripping and reduces slippage of tissue gripped between the compression pad 162 and the cutting electrode 149 FIG. 9 ) and / or the jaw member 142.

[0070] Turning to FIG. 12 to FIG. 15 , the compression pads 1262, 1362, 1462, 1562 are shown to include variable stiffness and / or other properties in at least one dimension thereof. The compression pads 1262, 1362, 1462, 1562 are shown to define a rectangular prismatic configuration, but any other suitable shape configuration is also envisioned. To vary the stiffness and / or other properties of the compression pads 1262, 1362, 1462, 1562, the compression pads 1262, 1362, 1462, 1562 can include different materials forming different portions thereof, as detailed below.

[0071] As shown in FIG. 12 , the compression pad 1262 includes a first compression pad portion 1264 and a second compression pad portion 1266. The first compression pad portion 1264 and the second compression pad portion 1266 are stacked on top of one another, with the first compression pad portion 1264 defining a tissue-contacting surface 1268 of the compression pad 1262, and the second compression pad portion 1266 configured to at least partially recess within the jaw member 142 FIG. 9The compression pad 1262 is contained within the compression pad and is therefore at least partially not exposed. The first compression pad portion 1264 and the second compression pad portion 1266 of the compression pad 1262 may define different hardnesses. For example, the first compression pad portion 1264 and the second compression pad portion 1266 of the compression pad 1262 may both be elastically compressible elastomers with different hardnesses, such that when the compression pad 1262 is compressed in the height direction of the compression pad 1262, one of the first compression pad portion 1264 or the second compression pad portion 1266 is at least partially compressed before the other of the first compression pad portion 1264 and the second compression pad portion 1266 is compressed, and / or compressed more than the other of the first compression pad portion 1264 and the second compression pad portion 1266. In other respects, one of the first compression pad portion 1264 and the second compression pad portion 1266 is an elastically compressible elastomer, while the other of the first compression pad portion 1264 and the second compression pad portion 1266 substantially resists compression during normal use conditions.

[0072] Alternatively or additionally, the first compression pad portion 1264 and the second compression pad portion 1266 may differ in thermal conductivity. For example, one of the first compression pad portion 1264 and the second compression pad portion 1266 may be thermally conductive, while the other of the first compression pad portion 1264 and the second compression pad portion 1266 may be an insulator. Similarly, one of the first compression pad portion 1264 and the second compression pad portion 1266 may include a filler material, while the other of the first compression pad portion 1264 and the second compression pad portion 1266 may not include a filler material, include different filler materials, or include different amounts (by weight or volume) of filler material.

[0073] refer to FIG. 13 Compression pad 1362 includes a first proximal compression pad portion 1364 and a second distal compression pad portion 1366. The first compression pad portion 1364 and the second compression pad portion 1366 are aligned with each other in a proximal-to-distal direction, wherein the first compression pad portion 1364 defines a proximal tissue contact surface 1368a of the compression pad 1362, and the second compression pad portion 1366 defines a distal tissue contact surface 1368b of the compression pad 1362. The first compression pad portion 1364 and the second compression pad portion 1366 of the compression pad 1362 can be described above with respect to the first compression pad portion 1264 and the second compression pad portion 1266 of the compression pad 1262 (… FIG. 12The details described differ from each other in any way. In one particular embodiment, the first compression pad portion 1364 and the second compression pad portion 1366 are both elastically compressible elastomers with different hardnesses. For example, the first proximal compression pad portion 1364 may define a first hardness, while the second distal compression pad portion 1366 defines a second, greater hardness, such that when the gripper members 142, 144 are closed to clamp the compression pad 1362 and the cutting electrode 149 (see...). FIG. 9 When tissue is between the two sides, the first proximal compression pad portion 1364 compresses a relatively larger amount than the second distal compression pad portion 1366, thereby facilitating the application of substantially uniform or more uniform force to the tissue along the length of the compression pad 1362 and / or along the length of the compression pad 1362 at the tissue contact surfaces 146, 148. FIG. 9 The gap distance between them is defined as substantially uniform or more uniform, assuming a distance of 150 degrees from the pivot. FIG. 8A and FIG. 8B Compared to the position of ), at a position closer to the pivot 150 ( FIG. 8A and FIG. 8B At the location of ), the force can be greater and / or the gap distance smaller.

[0074] refer to FIG. 14 The compression pad 1462 includes a first right-side compression pad portion 1464 and a second left-side compression pad portion 1466. The first compression pad portion 1464 and the second compression pad portion 1466 span the gripper member 142. FIG. 9 The compression pads 1462 and 1466 are positioned side-by-side, wherein the first compression pad portion 1464 defines the right tissue contact surface 1468a of the compression pad 1462, and the second compression pad portion 1466 defines the left tissue contact surface 1468b of the compression pad 1462. The first compression pad portion 1464 and the second compression pad portion 1466 of the compression pad 1462 can be defined above regarding the first compression pad portion 1264 and the second compression pad portion 1266 of the compression pad 1262 (…). FIG. 12The details described may differ from each other in any way. In one particular embodiment, the first compression pad portion 1464 and the second compression pad portion 1466 are both elastically compressible elastomers with different hardnesses. For example, the first compression pad portion 1464 may define a first hardness, while the second compression pad portion 1466 defines a different second hardness. In various aspects, the compression pad 1462 is configured for use with a laterally bending gripper member, wherein the first compression pad portion 1464 is disposed toward the inner edge or concave edge of the bending gripper member, while the second compression pad portion 1466 is disposed toward the outer edge or convex edge of the bending gripper member. In such a configuration, the first compression pad portion 1464 may define a first hardness that is less than the second hardness of the second compression pad portion 1466, thus facilitating the application of substantially uniform or more uniform forces to the tissue across the width of the compression pad 1462, for example, assuming that the force may tend to be greater toward the inner edge or concave edge of the bending gripper member compared to the outer edge or convex edge.

[0075] FIG. 15 Compression pad 1562 is shown, which includes a first right-side compression pad portion 1564, a second left-side compression pad portion 1566, and a third center compression pad portion 1568. The first compression pad portion 1564, the second compression pad portion 1566, and the third compression pad portion 1568 span the gripper member 142. FIG. 9 The compression pads 1562 are positioned side by side. The first compression pad portion 1564 and the second compression pad portion 1566 of the compression pad 1562 may be similar to each other, while the third compression pad portion 1568 is similar to that described above with respect to the compression pad 1262. FIG. 12 The details described herein differ in any way from those of the first compression pad portion 1564 and the second compression pad portion 1566. In one particular embodiment, the first compression pad portion 1564, the second compression pad portion 1566, and the third compression pad portion are all elastically compressible elastomers, wherein the first compression pad portion 1564 and the second compression pad portion 1566 define a first hardness, while the third compression pad portion 1568 defines a different second hardness. The different second hardness may be greater than the first hardness to increase the force at the lateral center of the compression pad 1562, or may be less than the first hardness to contribute to a uniform or more uniform force distribution laterally across the compression pad 1562. In all respects, the third compression pad portion 1568 defines a force substantially equal to or greater than that of the cutting electrode 149 ( FIG. 9 The width of the cutting electrode 149 ( FIG. 9 ) at the close proximity of gripper components 142 and 144 ( FIG. 9) is urged into a third compression pad portion 1568. The first and second compression pad portions 1564, 1566 can define equal or different widths as compared to the third compression pad portion 1568. In other aspects, the first and second compression pad portions 1564, 1566 each define a thermal conductivity that is less than (similar or different) the thermal conductivity of the third compression pad portion 1568. Such a configuration can help to concentrate heat at the center of the compression pad 1562 (e.g., opposite the cutting electrode 149 FIG. 9 ) to help heat and, thus, cut tissue.

[0076] Turning to FIG. 16 to FIG. 19 , the compression pads 1662, 1762, 1862, 1962 are shown as including interruptions designed to vary the stiffness and / or other properties in at least one dimension thereof. The compression pads 1662, 1762, 1862, 1962 are shown as defining a rectangular prismatic configuration, although any other suitable shape configuration is also contemplated.

[0077] With reference to FIG. 16 , to vary the stiffness (and / or other properties) in at least one dimension of the compression pad 1662, the compression pad 1662 includes a plurality of hollow voids 1665 defined at least partially through the height or thickness of the compression pad 1662. The hollow voids 1665 can be spaced apart from and aligned to define one or more longitudinal rows extending proximally to distally along at least a portion of the length of the compression pad 1662 (as shown), can be spaced apart from and aligned to define one or more lateral rows extending laterally across at least a portion of the width of the compression pad, can be defined toward one side of the compression pad 1662, can be defined toward one end of the compression pad 1662, can be defined along the center or side of the compression pad 1662, and / or can be defined in any other suitable manner. The hollow voids 1665 at least near each hollow void 1665 increase the compressibility of the compression pad 1662, and thus, the hollow voids 1665 can be used to increase the compressibility of the compression pad 1662 at certain locations or portions of the compression pad 1662 (decrease the effective stiffness of the compression pad 1662).

[0078] With reference to FIG. 17 , in aspects, to vary the stiffness (and / or other properties) in at least one dimension of the compression pad 1762, the compression pad 1762 includes a plurality of filled voids 1765 defined at least partially through the height or thickness of the compression pad 1762 and at least partially filled with a filler 1767 that is different than the material forming the body of the compression pad 1762. The filled voids 1765 can be arranged in any of the configurations detailed above with respect to the compression pad 1662 FIG. 16 ) or in any other suitable configuration.

[0079] The filler 1767 can define a hardness greater than that of the body of the compression pad 1762 to define an area of reduced compression, or can define a hardness less than that of the body of the compression pad 1762 to define an area of increased compression. Alternatively or additionally, the filler 1767 can define a texture different from that of the body of the compression pad 1762 to provide a greater or lesser tissue gripping texture in certain areas of the compression pad 1762, and / or can define a thermal conductivity different from that of the body of the compression pad 1762 to provide a greater or lesser thermal conductivity in certain areas of the compression pad 1762.

[0080] FIG. 18 and FIG. 19 Compression pads 1862, 1962 are shown that include hollow voids 1865 and filled voids 1965 defined at least partially through the length of the compression pads 1862, 1962, respectively. The compression pads 1862, 1962 can otherwise be configured according to any of the aspects of the respective compression pads 1662, 1762 detailed above ( FIG. 16 and FIG. 17 ), except for the orientation of the hollow voids 1865 and filled voids 1965. It is alternatively or additionally contemplated that the hollow voids and / or filled voids can be defined at least partially through the width of the compression pads in a similar manner as detailed above with respect to the compression pads 1662, 1762 ( FIG. 16 and FIG. 17 ).

[0081] Turning to FIG. 20 to FIG. 27 , in accordance with the present disclosure, the compression pad itself can be configured and / or configured relative to the jaw member 142 to provide a suitable force or force distribution along and / or across the jaw member 142. For example, as shown in FIG. 20 , the compression pad 2062 is disposed within the slot 161 of the jaw member 142. More particularly, the compression pad 2062 substantially fills the entire slot 161 and extends to a degree that is substantially coplanar relative to the tissue contact surface 146 (although the compression pad 2062 defines a cutout 2069) such that a portion of the compression pad 2062 is recessed within the slot 161 relative to the tissue contact surface 146. The cutout 2069 can be laterally centered within the compression pad 2062 such that lateral side portions of the compression pad 2062 extend to a relationship that is substantially coplanar with the tissue contact surface 146, while a central portion of the compression pad 2062 remains recessed relative to the tissue contact surface 146. Such a configuration can at least partially account for the cutting electrode 149 ( FIG. 9 ), thereby allowing the cutting electrode 149 to be in close proximity to the slot 161 of the jaw member 142, 144 (see FIG. 9) extends at least partially into the cutout 2069. However, other configurations of the cutout 2069 defined within the compression pad 2062 are also contemplated. The compression pad 2062 can define portions having different durometers and / or other characteristics similar to any of the aspects described above.

[0082] Referring to FIG. 21 , the compression pad 2162 is disposed within the slot 161 of the jaw member 142 and is recessed entirely within the slot 161 relative to the tissue contact surface 146. The compression pad 2162 can define a substantially planar exposed surface 2163 or, as shown, can define a varying profile in the width dimension of the exposed surface 2163 such as a triangular wave configuration (as shown), a sinusoidal wave configuration, a square wave configuration, one or more protrusions and / or depressions, a convex or concave exposed surface 2163 or portions thereof, etc. The compression pad 2162 can define portions having different durometers and / or other characteristics similar to any of the aspects described above.

[0083] Referring to FIG. 22 , the slot 2261 of the jaw member 142 defines a varying width along the height dimension thereof such as defining an hourglass configuration (as shown), although other configurations are also contemplated. The compression pad 2262 substantially fills the entire slot 2261 and can define a shape complementary to the slot 2261 or can assume the shape of the slot 2261 due to compression of the compression pad 2262 during installation into the slot 2261 or formation within the slot. The reduction in width in the compression pad 2262 and replacement of at least the reduced width area with the substantially rigid distal body 143b of the jaw member 142 reduces the compressibility of the compression pad 2262 and thus increases the effective durometer on at least a portion of the compression pad 2262. The compression pad 2262 can also define portions having different durometers and / or other characteristics similar to any of the aspects described above.

[0084] FIG. 23 The compression pad 2362 is shown disposed within the slot 161 of the jaw member 142 and protruding from the slot 161 toward the jaw member 142 FIG. 9 . Further, this protruding portion of the compression pad 2362 also extends laterally outward to partially overlap the tissue contact surface 146 on both sides of the slot 161. In some aspects, the compression pad 2362 further defines a cutout 2369 through the tissue contact surface 2368 thereof, although additional or alternative features of the tissue contact surface 2368 are also contemplated. The compression pad 2362 can also define portions having different durometers and / or other characteristics similar to any of the aspects described above.

[0085] Referring to FIG. 24 and FIG. 25In aspects, the slots 2461, 2561 of the jaw member 142 define release recesses 2472, 2572 within the opposing sidewalls that define the slots 2461, 2561. The release recesses 2472, 2572 can extend all or a portion of the length of the slots 2461, 2561, and can define any suitable configuration, such as a rectangular ( FIG. 24 ), triangular ( FIG. 25 ), rounded, or the like. Further, the release recesses 2472, 2572 can be disposed at an intermediate position along the height of the slots 2461, 2561 (see FIG. 24 ), at the closed end of the slots 2461, 2561 (see FIG. 5 ), or at any other suitable position. Multiple release recesses 2472, 2572 are also contemplated. In an initial, at-rest state of the compression pads 2462, 2562, the release recesses 2472, 2572 are substantially unfilled. However, upon compression of the compression pads 2462, 2562, the compression pads 2462, 2562 are at least partially urged into the release recesses 2472, 2572. Thus, by providing release recesses 2472, 2572 within the slots 2461, 2561, further compression of the compression pads 2462, 2562 is permitted, thereby reducing the effective stiffness of the compression pads 2462, 2562. The compression pads 2462, 2562 can also define portions having different stiffnesses and / or other properties similar to any of the aspects described above.

[0086] Referring to FIG. 26 and FIG. 27 , in aspects, unlike the release recesses defined with the slots 161 of the jaw member 142, the compression pads 2662, 2762 can occupy only a portion of the slots 161 in their at-rest position, such that the compression pads 2662, 2762 are able to expand outward (and, in aspects, downward) in response to compression thereof from the tissue-contacting surfaces 2668, 2768 of the compression pads 2662, 2762. When the compression pads 2662, 2762 are compressed in this manner, the compression pads 2662, 2762 are at least partially urged into the previously-unoccupied portions of the slots 161. Thus, the effective stiffness of the compression pads 2662, 2762 is reduced. The compression pads 2662, 2762 can also define portions having different stiffnesses and / or other properties similar to any of the aspects described above.

[0087] With particular reference to FIG. 26The compression pad 2662 defines a substantially solid configuration and is disposed within the slot 161 to substantially fill the open end of the slot 161, and because the volume (and shape) of the compression pad 2662 is less than the volume (and shape) of the slot 161, the unoccupied void of the slot 161 is enclosed within the slot 161 between the portion of the distal body 143b of the jaw member 142 that defines the slot 161 and the compression pad 2662. Turning specifically to FIG. 27 The compression pad 2762 is disposed within the slot 161 and defines a hollow interior, such as an arched configuration having a hollow concave interior, such that the unoccupied void of the slot 161 is enclosed within the slot 161 between the portion of the distal body 143b of the jaw member 142 that defines the slot 161 and the compression pad 2762, and within the hollow interior of the compression pad 2762.

[0088] Turning specifically to FIG. 28 And FIG. 29 In aspects, the compression pads 2862, 2962 are formed in multiple stages. For example, the compression pads 2862, 2962 can be formed via a two-shot overmolding or injection molding process, for example, where a first shot forms a first portion 2874, 2974 of the compression pads 2862, 2962, and a second shot forms a second portion 2876, 2976 of the compression pads 2862, 2962. As another example, the first portion 2874, 2974 of the compression pads 2862, 2962 can be pre-formed, and the second portion 2876, 2976 of the compression pads 2862, 2962 can then be formed around or within the first portion 2874, 2974 and within the slot 2861, 2961 of the jaw member 142, for example, via overmolding or injection molding. The first portion 2874, 2974 and the second portion 2876, 2976 can be formed from different materials, respectively, or otherwise configured to define portions having different durometers and / or other properties similar to those detailed above.

[0089] With particular reference to FIG. 28 The compression pad 2862 can be formed by a first overmolding step forming a first portion 2874 including first and second segments that line the lateral walls on either side of the slot 2861, and a second overmolding step forming a second portion 2876 between the first and second segments of the first portion 2874 and filling the remainder of the slot 2861. In particular, with regard to FIG. 29In any of the above aspects, the compression pad 2962 can be formed by a first overmolding step forming a first portion 2974 comprising a central body spaced apart from the lateral walls of the slot 2961 and recessed relative to the open end of the slot 2961, and a second overmolding step forming a second portion 2976 surrounding the first portion 2974 and filling the remainder of the slot 2961. In any of the above aspects, the jaw member 142 can comprise an access aperture 2878, 2978 extending through a bottom surface of the jaw member in communication with the slot 2861, 2961 to enable injection of overmolding material into the slot 161 during at least one of the overmolding steps.

[0090] Turning to FIG. 30 The compression pad 3062 can be configured similar to any of the compression pads detailed above and configured to extend longitudinally along the jaw member 142 (e.g., in alignment with the cutting electrode 149) and protrude from the jaw member 142 toward the jaw member 144. More particularly, the compression pad 3062 defines a tissue-contacting surface 3068 and is tapered in height (e.g., the extent to which the tissue-contacting surface 3068 protrudes from the jaw member 142 toward the jaw member 144). For example, as illustrated, the height of the compression pad 3062 can taper in a distal-to-proximal direction along at least a portion of the length of the compression pad 3062 such that the tissue-contacting surface 3068 angles proximally along at least a portion of the length of the compression pad 3062. Such a configuration can provide a uniform or more uniform clamping pressure applied to tissue clamped between the compression pad 3062 and the cutting electrode 149 along the length of the jaw members 142, 144 and / or a uniform or more uniform gap distance between the jaw members 142, 144 along the length of the jaw members 142, 144 as the tapered height of the compression pad 3062 offsets the tendency for greater pressure and smaller gap distance toward the pivot 150 as compared to being distal therefrom. Other configurations are also envisioned.

[0091] While several aspects of the present disclosure have been shown and described herein, it is to be understood that the present disclosure is not limited to the aspects described, as such may include any number of additional aspects, examples of which are set forth in the following numbered clauses:

Claims

1. A surgical end effector assembly, comprising: A first gripper member and a second gripper member, the first gripper member and the second gripper member including corresponding first tissue contact surfaces and second tissue contact surfaces, at least one of the first gripper member or the second gripper member being movable relative to the other of the first gripper member or the second gripper member between a spaced-apart position and a proximal position to clamp tissue between the first tissue contact surface and the second tissue contact surface. The second gripper member includes a cutting electrode that extends from the second gripper member toward the first gripper member. The first gripper member includes a compression pad configured to be opposite the cutting electrode at a proximity position of the first gripper member and the second gripper member, so as to clamp tissue between the cutting electrode and the compression pad at the proximity position of the first gripper member and the second gripper member. The compression pad includes a first portion having a first hardness and a second portion having a second hardness different from the first hardness.

2. The surgical end effector assembly according to claim 1, wherein, The first and second portions of the compression pad are stacked vertically such that the first portion is configured to contact tissue, while the second portion is substantially not exposed within the first gripper member.

3. The surgical end effector assembly according to claim 1, wherein, The first and second portions of the compression pad are longitudinally aligned such that the first portion defines a proximal portion of the compression pad and the second portion defines a distal portion of the compression pad.

4. The surgical end effector assembly according to claim 1, wherein, The first and second portions of the compression pad are laterally aligned such that the first portion defines the right side portion of the compression pad and the second portion defines the left side portion of the compression pad.

5. The surgical end effector assembly according to claim 1, wherein, The first portion of the compression pad includes a first outer section and a second outer section, wherein a second portion of the compression pad is disposed between the first outer section and the second outer section.

6. The surgical end effector assembly according to claim 1, wherein, The first part includes the body of the compression pad, and the second part includes a plurality of voids defined through the body of the compression pad.

7. The surgical end effector assembly according to claim 6, wherein, At least one of the multiple voids is filled with a material different from the material of the body forming the compression pad.

8. The surgical end effector assembly according to claim 1, wherein, The first part is a first overmolded part, and the second part is a second overmolded part.

9. The surgical end effector assembly according to claim 1, wherein, The second part surrounds at least a portion of the first part.

10. The surgical end effector assembly of claim 1, wherein, The first part includes a first filler material, and the second part includes a different second filler material or does not include a filler material.

11. A surgical end effector assembly, comprising: A first gripper member and a second gripper member, the first gripper member and the second gripper member including corresponding first tissue contact surfaces and second tissue contact surfaces, at least one of the first gripper member or the second gripper member being movable relative to the other of the first gripper member or the second gripper member between a spaced-apart position and a proximal position to clamp tissue between the first tissue contact surface and the second tissue contact surface. The second gripper member includes a cutting electrode that extends from the second gripper member toward the first gripper member. The first gripper member includes a compression pad disposed within a slot defined through the first tissue contact surface. The compression pad is configured to face the cutting electrode at a proximal position of the first and second gripper members to clamp tissue between the cutting electrode and the compression pad. The cutting electrode at least partially compresses the compression pad from an initial state to a compressed state at the proximal position of the first and second gripper members. In this initial state, a portion of the compression pad is spaced apart from the wall defining the slot, and In this compressed state, the portion of the compression pad is pushed against and comes into contact with the wall defining the slot.

12. The surgical end effector assembly of claim 11, wherein, The groove includes at least one release recess, wherein the wall defining the groove is disposed within the release recess.

13. The surgical end effector assembly of claim 12, wherein, The at least one recess includes a pair of release recesses disposed on both sides of the compression pad.

14. The surgical end effector assembly of claim 10, wherein, This wall is the side wall of the trench.

15. The surgical end effector assembly of claim 10, wherein, The compression pad defines a volume smaller than the volume of the groove, such that in the initial state, a recess is defined between the compression pad and the wall defining the groove.

16. A surgical instrument, comprising: case; A shaft assembly that extends distally from the housing; as well as An end effector assembly extending distally from the shaft assembly, the end effector assembly comprising: A first gripper member and a second gripper member, the first gripper member and the second gripper member including corresponding first tissue contact surfaces and second tissue contact surfaces, at least one of the first gripper member or the second gripper member being movable relative to the other of the first gripper member or the second gripper member between a spaced-apart position and a proximal position to clamp tissue between the first tissue contact surface and the second tissue contact surface. The second gripper component includes a cutting electrode that extends from the second gripper component toward the first gripper component. The first gripper member includes a compression pad configured to face the cutting electrode at a proximity position between the first and second gripper members, so as to clamp the tissue disposed between the cutting electrode and the compression pad at the proximity position between the first and second gripper members. The compression pad defines varying compressibility in at least one dimension of the compression pad.

17. The surgical instrument according to claim 16, wherein, The compression pad comprises sections formed of different materials, thereby defining the compressibility of the variation.

18. The surgical instrument according to claim 16, wherein, The compression pad is at least partially disposed within a slot defined within the first gripper member, wherein the slot defines a varying width, thereby altering the width of the compression pad and defining the varying compressibility.

19. The surgical instrument according to claim 16, wherein, The compression pad is at least partially disposed within a slot defined within the first gripper member, the varying compressibility being defined by a first portion of the compression pad extending into a previously unoccupied portion of the slot in response to compression of the compression pad and a second portion of the compression pad being pushed against the wall of the slot in response to compression of the compression pad.

20. The surgical instrument according to claim 16, wherein, The change in compressibility corresponds at least in part to the change in the force applied to the tissue held between the cutting electrode and the compression pad at the close proximity of the first and second gripper members.

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