Techniques for controlling clamp force of a surgical instrument during operating modes

Abstract

A surgical instrument and an associated method for controlling the clamping force of the surgical instrument, the surgical instrument comprising: an end effector having a jaw assembly movable between an open state and a closed state; a trigger assembly operable to move the jaw assembly of the end effector between the open state and the closed state; and a clamping force enhancement system controllable to increase the clamping force of the jaw assembly of the end effector. A controller of the surgical instrument is configured to activate the clamping force enhancement system in response to (ii) the activation of an RF mode of the surgical instrument and (ii) a position sensor indicating that the current state of the jaw assembly is closed, to increase the clamping force of the jaw assembly of the end effector.

Description

Technical Field

[0001] This disclosure relates generally to energy-based surgical instruments, and more specifically to surgical instruments and associated methods for controlling the clamping force of the surgical instruments. Background Technology

[0002] Energy-based surgical instruments are increasingly used in surgical procedures due to their unique performance characteristics. Depending on the specific device configuration and operating parameters, energy-based surgical instruments can provide both transverse incisions of tissue and tissue hemostasis through coagulation, which can reduce or otherwise minimize patient trauma. Depending on the specific application, energy-based surgical instruments can utilize various surgical techniques, including, for example, ultrasound and / or electrosurgery (e.g., radiofrequency (RF)).

[0003] Typical ultrasonic surgical instruments may include a handheld component comprising an ultrasonic transducer and a slender shaft assembly with a distally mounted end effector for cutting and sealing tissue. For example, the end effector may include a jaw assembly with an ultrasonic scalpel and a gripping arm, the gripping arm including a non-adhesive tissue pad or similar base to receive the ultrasonic scalpel. In some cases, the slender shaft assembly may be permanently attached to the handheld component. In other cases, such as in the presence of disposable shaft assemblies or shaft assemblies interchangeable between different handheld components, the slender shaft assembly may be detached from the handheld component. In use, the end effector transmits ultrasonic energy to the tissue in contact with the ultrasonic scalpel of the end effector to achieve cutting and sealing actions. Such ultrasonic surgical devices can be configured for open surgical purposes, laparoscopic and / or endoscopic surgical procedures, including robot-assisted procedures.

[0004] Ultrasonic energy uses temperatures lower than those used in electrosurgical procedures to cut and coagulate tissue. Through high-frequency vibrations (e.g., 55,500 times per second), the ultrasonic scalpel denatures proteins in the tissue to form a viscous coagulate. The pressure applied to the tissue by the surface of the ultrasonic scalpel causes blood vessels to collapse and the coagulate to form a hemostatic seal. The surgeon can control the cutting speed and coagulation by the force applied to the tissue by the end effector, the duration of that force application, and the selected offset level of the end effector.

[0005] In electrosurgical instruments, one or more electrodes are incorporated into an end effector and configured to apply a therapeutic current to the patient's tissue to form a hemostatic seal. In electrosurgical instruments that do not include harmonic modes (i.e., do not include harmonic blades), the end effector may be embodied as two gripping arms or jaws. In such embodiments, the electrosurgical instrument may include a separate mechanical blade or knife for cutting tissue after the hemostatic seal has been formed, which may be incorporated into an elongated shaft attached to the end effector. In bipolar embodiments, an active electrode is attached to one of the gripping arms of the end effector and configured to introduce current into the tissue, which is received by a return electrode attached to the other gripping arm of the end effector (or, in embodiments including harmonic modes, as the knife itself). Conversely, in unipolar embodiments, the return electrode (e.g., a "grounding pad") may be separate from the electrosurgical instrument and located on a different part of the patient's body. In some embodiments, the electrosurgical instrument may also be configured to apply a subtherapeutic current to the patient's tissue, which may be used for sensing purposes (e.g., measuring tissue impedance).

[0006] Electrosurgery creates a hemostatic seal by generating heat in the tissue via introduced electrical energy, which is embodied in radio frequency (“RF”) energy. The specific frequency used can vary from about 100 kHz to 1 MHz depending on the intended use of the electrosurgical instrument, but higher frequencies may be used in some implementations. Additionally, in some cases, sub-therapeutic frequencies may be used for purposes other than hemostatic sealing, such as performing various electrical measurements on the tissue.

[0007] It should be understood that some energy-based surgical instruments can employ bimodal or multimodal techniques to perform transverse incisions and / or hemostasis of patient tissue. For example, in some cases, energy-based surgical instruments may include both ultrasound and electrosurgical functions (e.g., by utilizing an ultrasonic scalpel as an electrode for the electrosurgical mode), which increases the surgical options offered to the surgeon by the surgical instrument. Summary of the Invention

[0008] According to one aspect of this disclosure, a surgical instrument may include an end effector, a trigger assembly, a clamping force enhancement system, and a controller. The end effector may include a jaw assembly movable between an open and closed state, and an ultrasonic scalpel. The trigger assembly is operable to move the jaw assembly of the end effector between an open and closed state. Additionally, the trigger assembly may include a position sensor configured to generate sensor data indicating the current state of the jaw assembly of the end effector. The clamping force enhancement system may be controllable to increase the clamping force of the jaw assembly of the end effector. The controller may be configured to control the activation of an ultrasonic mode and a radio frequency (RF) mode of the surgical instrument. The controller may also be configured to activate the clamping force enhancement system to increase the clamping force of the jaw assembly of the end effector in response to (i) the RF mode being activated and (ii) the position sensor indicating that the current state of the jaw assembly is closed.

[0009] In some embodiments, the trigger assembly may include a mode switch selectable to instruct the controller to activate an RF mode. Additionally, in some embodiments, activating the clamping force enhancement system may include engaging a first clamping force gear and a second clamping force gear of the clamping force enhancement system to increase the clamping force of the jaw assembly of the end effector. In such embodiments, the trigger assembly may include a bracket configured to move along a bracket axis in response to operation of the trigger assembly, thereby moving the jaw assembly of the end effector between an open and closed state. Furthermore, the clamping force enhancement system may include a clamping force motor including a first clamping force gear, and wherein the bracket includes a second clamping force gear.

[0010] Additionally, in some embodiments, the bracket may include a channel having an opening defined at a proximal end of the bracket. In such embodiments, a second clamping force gear may be located within the channel. Furthermore, a first clamping force gear of the clamping force motor may be configured to be received within the channel of the bracket to engage with the second clamping force gear when the clamping force enhancement system is activated. In such embodiments, the surgical instrument may also include a biasing spring coupled to the bracket and the clamping force motor. The biasing spring may be configured to bias the first clamping force gear away from the second clamping force gear along the bracket axis.

[0011] In some embodiments, the second clamping force gear may extend proximally away from the proximal end of the bracket. In such embodiments, the first clamping force gear may be configured to axially mesh with the second clamping force gear when the clamping force enhancement system is engaged. Additionally, in such embodiments, engagement of the first and second clamping force gears allows the bracket to move proximally along the bracket axis. Furthermore, in some embodiments, the controller may be configured to deactivate the clamping force enhancement system in response to (i) the activation of an ultrasonic mode or (ii) a position sensor indicating that the jaw assembly is not currently closed.

[0012] According to another aspect of this disclosure, a method for controlling the operation of a surgical instrument may include: determining, by a controller of the surgical instrument, whether the jaw assembly of an end effector of the surgical instrument is in a closed state based on sensor data generated by a position sensor of a trigger assembly of the surgical instrument; and determining, by the controller, whether a radio frequency (RF) mode of the surgical instrument has been activated. The method may further include, in response to determining that (i) the jaw assembly is in a closed state and (ii) the RF mode has been activated, activating, by the controller, a clamping force enhancement system of the surgical instrument to increase the clamping force of the jaw assembly of the end effector.

[0013] In some embodiments, activating the clamping force enhancement system may include engaging a first clamping force gear and a second clamping force gear of the clamping force enhancement system to increase the clamping force of the jaw assembly of the end effector. In such embodiments, activating the clamping force enhancement system may include inserting the first clamping force gear into a channel defined in the proximal end of a bracket of a trigger assembly of a surgical instrument to engage the second clamping force gear located within the channel. For example, engaging the first clamping force gear with the second clamping force gear may include moving the bracket proximally along the bracket axis.

[0014] In some embodiments, activating the clamping force enhancement system may include engaging a first clamping force gear with a second clamping force gear extending from the proximal end of the bracket of the trigger assembly of the surgical instrument. For example, engaging the first clamping force gear with the second clamping force gear may include axially meshing the first clamping force gear with the second clamping force gear. In some embodiments, the method may further include deactivating the clamping force enhancement system by the controller in response to (i) determining by the controller that the RF mode has been deactivated or (ii) determining by the controller that the jaw assembly of the end effector is not in a closed state.

[0015] According to another aspect of this disclosure, the surgical instrument may include an end effector, a trigger assembly, a clamping force enhancement system, and a controller. The end effector may include a jaw assembly movable between an open and closed state, and an ultrasonic scalpel. The trigger assembly is operable to move the jaw assembly of the end effector between the open and closed states. Additionally, the trigger assembly may include a position sensor configured to generate sensor data indicating the current state of the jaw assembly of the end effector, and the bracket configured to move along a bracket axis in response to operation of the trigger assembly to move the jaw assembly of the end effector between the open and closed states. The clamping force enhancement system may be controllable to increase the clamping force of the jaw assembly of the end effector. The clamping force enhancement system may include a first clamping force gear coupled to a clamping force motor and a second clamping force gear coupled to the bracket. The controller may be configured to control the activation of a radio frequency (RF) mode of the surgical instrument. Additionally, the controller can be configured to activate the clamping force enhancement system in response to determining that (i) the RF mode is activated and (ii) the jaw assembly is closed, so that the first clamping force gear engages with the second clamping force gear.

[0016] In some embodiments, the bracket may include a channel having an opening defined at a proximal end of the bracket. In such embodiments, a second clamping force gear may be located within the channel. Alternatively, in such embodiments, engaging the first clamping force gear with the second clamping force gear may include receiving the first clamping force gear within the channel of the bracket. Attached Figure Description

[0017] The specific implementation method refers to the following figures, in which:

[0018] Figure 1 A schematic diagram of one embodiment of a system for controlling the clamping force of surgical instruments;

[0019] Figure 2 for Figure 1 A perspective view of an implementation of a system of surgical instruments;

[0020] Figure 3 It is in the open state Figure 2 A side front view of the jaw assembly of the end effector of a surgical instrument;

[0021] Figure 4 For being in a closed state Figure 2 A side front view of the jaw assembly of the end effector of a surgical instrument;

[0022] Figure 5 for Figure 2 Exploded view of the handle assembly of a surgical instrument;

[0023] Figure 6 for Figure 2 A block diagram of one embodiment of a clamping force enhancement system for a surgical instrument, including a pair of clamping force gears;

[0024] Figure 7 for Figure 6 A side front view of one embodiment of the clamping force enhancement system, wherein one of the clamping force gears is located Figure 2 Within the channel of the trigger system of the surgical instruments;

[0025] Figure 8 for Figure 6 A side front view of an implementation scheme of a clamping force enhancement system, wherein the clamping force enhancement system is in a deactivated state;

[0026] Figure 9 for Figure 6 A side front view of an implementation of a clamping force enhancement system, wherein the clamping force enhancement system is in an active state;

[0027] Figure 10 for Figure 6 A side front view of another embodiment of the clamping force enhancement system, wherein one of the clamping force gears is attached to Figure 2 The proximal end of the trigger system of the surgical instrument is shown as being in a deactivated state;

[0028] Figure 11 for Figure 10 A side front view of an implementation of a clamping force enhancement system, wherein the clamping force enhancement system is in an active state;

[0029] Figure 12 for Figure 2 A simplified block diagram of an embodiment of the control circuit for a surgical instrument; and

[0030] Figure 13A and Figure 13B A simplified flowchart of one embodiment of a method for controlling the clamping force of surgical instruments, which can be derived from... Figure 12 The control circuit executes. Detailed Implementation

[0031] While the concepts of this disclosure are readily available in various modifications and alternatives, specific exemplary embodiments thereof have been shown by way of example in the accompanying drawings and will be described in detail herein. However, it should be understood that this disclosure is not intended to limit the concepts to the specific forms disclosed, but rather, the object of the invention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the invention as defined by the appended claims.

[0032] Throughout this specification, when referring to orthopedic implants and surgical instruments described herein, as well as the natural anatomy of a patient, terms indicating anatomical reference, such as anterior, posterior, medial, lateral, superior, inferior, etc., may be used. These terms have well-known meanings in anatomical studies and orthopedic surgery. Unless otherwise stated, these anatomical reference terms used in the written details and claims are intended to be consistent with their well-known meanings.

[0033] References to "an embodiment," "an embodiment," "an exemplary embodiment," etc., in this specification mean that the embodiment may include a particular feature, structure, or characteristic, but each embodiment may or may not include that particular feature, structure, or characteristic. Furthermore, these phrases do not necessarily refer to the same embodiment. Additionally, when a particular feature, structure, or characteristic is described in connection with an embodiment, whether or not it is explicitly described, it should be assumed that implementing such a particular feature, structure, or characteristic in combination with other embodiments is within the knowledge of a person skilled in the art. Furthermore, it should be understood that items included in a list in the form of "at least one of A, B, and C" may mean (A); (B); (C); (A and B); (A and C); (B and C); or (A, B, and C). Similarly, items listed in the form of "at least one of A, B, or C" may mean (A); (B); (C); (A and B); (A and C); (B and C); or (A, B, and C).

[0034] In some cases, the disclosed embodiments may be implemented in hardware, firmware, software, or any combination thereof. The disclosed embodiments may also be implemented as instructions carried or stored on a transient or non-transitory machine-readable (e.g., computer-readable) storage medium, which may be read and executed by one or more processors. The machine-readable storage medium may be embodied in any storage device, mechanism, or other physical structure (e.g., volatile or non-volatile memory, media disk, or other media device) for storing or transmitting information in a machine-readable form.

[0035] In the accompanying drawings, certain structural or methodological features may be shown in a specific arrangement and / or order. However, it should be understood that such a specific arrangement and / or order may not be necessary. Instead, in some embodiments, such features may be arranged in a different manner and / or order than those shown in the illustrative drawings. Furthermore, the inclusion of structural or methodological features in a particular drawing does not imply that such features are necessary in all embodiments, and in some embodiments, these features may be omitted or may be combined with other features.

[0036] See now Figure 1 and Figure 2In one exemplary embodiment, a system 100 for controlling the clamping force of a surgical instrument includes a multi-mode (e.g., ultrasound mode and radio frequency (RF) mode) surgical instrument 102, a transducer 104, and a generator 106. In use, the surgical instrument 102 can be used to perform various surgical procedures, including laparoscopic, endoscopic, or conventional open surgical procedures. In doing so, the surgeon can selectively activate various modes of the surgical instrument, such as ultrasound mode and / or RF mode. In ultrasound mode, the generator 106 drives the transducer 104 to cause the ultrasonic scalpel 130 of the jaw assembly 122 of the end effector 120 of the surgical instrument 102 to vibrate at a reference frequency, which facilitates simultaneous cutting of patient tissue and hemostatic sealing. In RF mode, the generator 106 delivers a quantity of therapeutic RF energy to the patient tissue to achieve hemostatic sealing. In such embodiments, the scalpel 130 may be embodied as an ultrasonic scalpel 130 or a mechanical scalpel designed to use mechanical force to cut tissue (e.g., in those embodiments that do not employ ultrasound technology).

[0037] As discussed in more detail below, when the surgical instrument 102 is in RF mode and the jaw assembly 122 is moved to the closed position, the clamping force enhancement system 600 (see below) Figure 6 The jaw assembly 122 is activated to increase the clamping force of the jaw assembly 122 when in RF mode. In this way, the clamping force of the jaw assembly 122 applied to the tissue captured by the jaw assembly 122 is increased when the surgical instrument is in RF mode, relative to the clamping force of the jaw assembly 122 when in ultrasound mode or other operating modes.

[0038] Surgical instrument 102 is illustratively represented as surgical scissors, but in other embodiments it may be illustrative of other types of surgical instruments having multiple modes of operation. In an illustrative embodiment, surgical instrument 102 includes a handle assembly 110 and an elongated shaft assembly 112 extending distally away from the handle assembly 110 and, in some embodiments, removably attached to the handle assembly 110. The elongated shaft assembly 112 includes an end effector 120 located at a distal end remote from the handle assembly 110. The end effector 120 includes a jaw assembly 122, which illustratively includes an ultrasonic scalpel 130 and a corresponding jaw clamp 132. Figure 3 and Figure 4 As shown, the jaw assembly 122 can be in the open state ( Figure 3 ) and closed state ( Figure 4The jaw assembly 122 moves between the open and closed states. In the open state, the jaw clamp 132 is positioned away from the ultrasonic scalpel 130, and in the closed state, the jaw clamp 132 is positioned near or otherwise in contact with the ultrasonic scalpel 130. Actuation of the jaw assembly 122 from the open to the closed state allows for grasping, cutting, and coagulating blood vessels and / or tissues. It should be understood that the open state may correspond to a degree of opening less than the fully open position of the jaw assembly 122, and the closed state may correspond to a degree of closure less than the fully closed position. That is, the open state may, for example, correspond to a minimum or greater distance between the distal end of the jaw clamp 132 and the ultrasonic scalpel 130, and the closed state may correspond to a maximum or less distance between the distal end of the jaw clamp 132 and the ultrasonic scalpel 130. However, in other embodiments, the open state may correspond to the fully open position of the jaw assembly 122, and the closed state may correspond to the fully closed position of the jaw assembly 122.

[0039] like Figure 3 As shown, the jaw assembly 122 may include one or more electrodes 300 that are attached to or combined with the jaw gripper 132 and configured to deliver a amount of RF energy when the surgical instrument is in RF mode. Although in Figure 3 In some embodiments, the exemplary end effector 120 includes only a single electrode 300, but it should be understood that in other embodiments, the end effector 120 may include additional electrodes 300 (e.g., multiple electrode pads 300). Electrode 300 may be embodied as an active electrode configured to deliver RF energy or as a return electrode configured to “absorb” the applied RF energy. In those embodiments utilizing bipolar RF, the ultrasonic scalpel 130 may embody an active electrode or a return electrode, wherein electrode 300 embodies another active electrode or return electrode. Alternatively, other active electrodes or return electrodes may be incorporated into the ultrasonic scalpel 130 or into another portion of the jaw assembly 122 of the end effector 120. In monopolar embodiments, the RF electrode 300 may be embodied as an active electrode, and the return electrode may be attached to a portion of the patient's body.

[0040] See again Figure 1 and Figure 2The handle assembly 110 includes a receiver 140 configured to receive a transducer 104 to facilitate connection of the transducer 104 to the handle assembly 110 and the elongated shaft assembly 112. The handle assembly 110 also includes a trigger assembly 150 comprising a main trigger 152 and a switch assembly 154. The main trigger 152 is operable by a surgeon to move the jaw assembly 122 of the end effector 120 between an open and closed state. The switch assembly 154 includes one or more buttons operable by a surgeon to activate (and in some embodiments, configure) various modes of the surgical instrument 102, such as switching between an ultrasound mode and an RF mode.

[0041] Transducer 104 is exemplarily connected to generator 106 via cable assembly 108. As described above, generator 106 is configured to drive transducer 104 at a reference frequency or resonant frequency, thereby causing ultrasonic scalpel 130 to vibrate. For example, in one exemplary embodiment, generator 106 may supply an electrical signal to transducer 104 to cause ultrasonic scalpel 130 of jaw assembly 122 to vibrate longitudinally in, for example, a range of approximately 20 kHz to 250 kHz. In a specific embodiment, for example, ultrasonic scalpel 130 may vibrate in a range of approximately 54 kHz to 56 kHz (e.g., at approximately 55.5 kHz). In other embodiments, ultrasonic scalpel 130 may vibrate at other frequencies, including, for example, approximately 31 kHz or approximately 80 kHz. The vibration offset of ultrasonic scalpel 130 can be controlled, for example, by controlling the amplitude of the electrical signal applied to transducer 104 by generator 106. Generator 106 may be activated such that electrical energy can be supplied to transducer 104 continuously or intermittently. The generator 106 also has a power cord (not shown) for plugging into an electrosurgical unit or a conventional power outlet. Alternatively, the generator 106 can be powered by a direct current (DC) source such as a battery.

[0042] In one exemplary embodiment, generator 106 may be configured to operate in different modes. Thus, exemplary generator 106 includes an ultrasound generator module 162 for controlling an ultrasound mode and an RF generator module 164 for controlling an RF mode or an electrosurgical mode of surgical instruments. In some embodiments, the various modes of generator 106 may operate independently of each other. For example, generator 106 may activate the ultrasound mode of ultrasound generator module 162 to apply ultrasound energy to jaw assembly 122, and subsequently, therapeutic or subtherapeutic RF energy may be applied to jaw assembly 122 via electrosurgical generator module 164. Alternatively, the activation modes of generator 106 may operate simultaneously or concurrently with each other.

[0043] In RF mode, the electrosurgical generator module 164 can be configured to generate RF energy at frequencies ranging from approximately 100 kHz to approximately 1 MHz. The generated RF energy is supplied to the patient's tissue via electrodes 300 of the end effector 120, as described above. Figure 3 In some embodiments, the RF module 164 may also be configured to selectively provide subtherapeutic levels of RF energy to perform various electrical measurements of patient tissue. For example, the RF generator module 164 may be configured to measure the impedance of patient tissue using electrodes 300 and an appropriate RF energy level.

[0044] Now for reference Figure 5 The handle assembly 110 exemplarily includes a housing 500, which includes a right half-housing 502 and a left half-housing 504. The half-housings 502 and 504 are configured to mate with each other to form the housing 500. To facilitate such mating, each of the half-housings 502 and 504 may include various interfaces sized to be mechanically aligned and engaged with each other to form the housing 500 and enclose the internal working parts of the surgical instrument 102.

[0045] The main trigger 152 of the trigger assembly 150 is coupled to a linkage mechanism to convert the rotational motion of the main trigger 152 into axial motion of the bracket 510 along the bracket axis 512. This axial motion is then configured to move the jaw assembly 122 of the end effector 120 between an open and closed state via the elongated shaft assembly 112. The main trigger 152 includes a first set of flanges 520 having openings formed therein to receive a first bracket pin 530 extending transversely through the bracket axis 512 through the bracket 510. The main trigger 152 also includes a second set of flanges 522 configured to receive a first end of a connector 524. A trigger pin 526 is received within the openings formed in the first end of the connector 524 and the second set of flanges 522. The trigger pin 526 forms a trigger pivot point for the main trigger 152. The second end of the connector 524, opposite the first end, is received in a slot formed in the proximal end of the bracket 510 and retained therein by a second bracket pin 532. When the main trigger 152 rotates about a pivot point formed by the trigger pin 526, the bracket 510 translates horizontally along the bracket axis 512. A spring 534 is used to bias the bracket 510 forward, such that the jaw assembly 122 of the end effector 120 is biased to an open (or fully open) state.

[0046] As described above, the trigger assembly 150 also includes a switch assembly 154. The switch assembly 154 exemplarily includes a toggle switch 540 selectable to activate one or more switches 542. Activation of the switches 542 electrically switches or otherwise selects various operating modes of the surgical instruments (e.g., ultrasound mode or RF mode).

[0047] The handle assembly 110 also includes a clamping force enhancement system 600. For example... Figure 6 As shown, the exemplary clamping force enhancement system 600 includes a clamping force motor 602 having a clamping force gear 610 operably attached thereto. For example, in an exemplary embodiment, the clamping force gear 610 is coupled to the shaft of the clamping force motor 602 to form a pinion of the clamping force motor 602. The clamping force enhancement system 600 also includes a clamping force gear 620 coupled to or otherwise incorporated in a bracket 510.

[0048] In use, when the trigger assembly 150 of the surgical instrument 102 is activated to move the jaw assembly 122 of the end effector 120 to a closed state, the carriage 510 moves proximally (or "rearwardly") along the carriage axis 512, causing the clamping force gear 620 of the carriage 510 to move close to the clamping force gear 610 of the clamping force motor 602. Therefore, when the clamping force enhancement system 600 is activated with the jaw assembly 122 in the closed state, the clamping force gear 610 of the clamping force motor engages with the clamping force gear 620 of the carriage 510. This engagement of the clamping force gears 610 and 620 causes the carriage 510 to move further proximally along the carriage axis 512, which further increases the clamping force applied by the jaw assembly 122. It should be understood that when the clamping force enhancement system 600 is activated, the clamping force motor 602 may optionally or additionally move toward the bracket 510 to cause the clamping engagement of the gears 610, 620.

[0049] In such Figure 7 In the exemplary embodiment shown, the bracket 510 of the trigger assembly 150 includes a channel 700 having an opening 702 defined in a proximal end 704 of the bracket 510. In such embodiments, a clamping force gear 620 is located within the channel 700, as shown. For example, the clamping force gear 620 may be embodied as an internal gear defined within the inner wall of the channel 700. Figure 7As shown, when the trigger assembly 150 is activated to close the jaw assembly 122 of the end effector 120, the bracket 510 moves proximally along the bracket axis 512, as indicated by arrow 750. As the bracket 510 moves proximally along the bracket axis 512, the clamping force gear 610 of the clamping force motor 602 is received in the channel 700 of the bracket 510, such that the clamping force gears 610, 620 are positioned close to each other or otherwise initially in contact with each other, as... Figure 8 As shown. When the jaw assembly 122 is in the closed state and the clamping force enhancement system 600 is activated, the clamping force gear of the clamping force motor 602 further engages the clamping force gear 620 of the bracket 510, causing the bracket to move further along the bracket axis 512 in the proximal direction indicated by arrow 750, which increases the clamping force of the jaw assembly 122. The resulting clamping force of the jaw assembly 122 can be controlled or otherwise modified by controlling the position of the bracket 510 along the bracket axis 512. Therefore, in some embodiments, the resulting clamping force can be adjusted within a range of clamping forces.

[0050] See now Figure 10 and Figure 11 In another embodiment, the clamping force gear 620 may be coupled to the proximal end 720. For example, as shown, the clamping force gear 620 may be attached to a non-rotating shaft 1000 extending from the proximal end 720 of the bracket 510. In such an embodiment, when the trigger assembly 150 is activated to close the jaw assembly 122 of the end actuator 120, the bracket 510 moves in the proximal direction along the bracket axis 512, as indicated by arrow 750. As the bracket 510 moves proximally along the bracket axis 512, the clamping force gear 620 of the bracket 510 moves to approach or otherwise contacts the clamping force gear 610 of the clamping force motor 602. When the jaw assembly 122 is in the closed state and the clamping force enhancement system 600 is activated, the clamping force gear of the clamping force motor 602 further engages the clamping force gear 620 of the bracket 510, so that the bracket moves further along the bracket axis 512 in the proximal direction indicated by arrow 750, as... Figure 11 As shown, this increases the clamping force of the jaw assembly 122. Similarly, the resulting clamping force of the jaw assembly 122 can be controlled or otherwise modified by controlling the position of the bracket 510 along the bracket axis 512.

[0051] See now Figure 12 In an exemplary embodiment, the surgical instrument 102 includes a control circuit 1200. The control circuit 1200 includes a controller 1202, a position sensor 1210, and a clamping force enhancement system 600. However, in other embodiments, the control circuit 1200 may include additional or other electronic devices and / or circuitry.

[0052] Controller 1202 may be embodied as any type of controller, function block, digital logic or other component, device, circuit or combination thereof capable of performing the functions described herein. In an exemplary embodiment, controller 1202 includes processor 1204, memory 1206 and input / output (I / O) subsystem 1208. Processor 1204 may be embodied as any type of processor capable of performing the functions described herein. For example, processor 1204 may be embodied as a single-core or multi-core processor, digital signal processor, microcontroller or other processor or processing / control circuitry. Similarly, memory 1206 may be embodied as any type of volatile and / or non-volatile memory or data storage device capable of performing the functions described herein. In operation, memory 1206 may store various data and software used during the operation of control circuitry 1200, such as executable firmware or software, programs, libraries and drivers that may be executed by processor 1204 or otherwise used.

[0053] Processor 1204 and memory 1206 are communicatively coupled to other components of control circuitry 1200 via I / O subsystem 1208, which may be embodied as circuitry and / or components to facilitate input / output operations between controller 1202 (e.g., processor 1204 and / or memory 1206) and other components of control circuitry 1200. For example, I / O subsystem 1208 may be embodied as or otherwise include a memory controller hub, input / output control hub, firmware devices, communication links (i.e., point-to-point links, bus links, wires, cables, optical fibers, printed circuit board traces, etc.) and / or other components and subsystems to facilitate input / output operations. In some embodiments, I / O subsystem 1208 may form part of a system-on-a-chip (SoC) and be integrated onto a single integrated circuit chip along with processor 1204, memory 1206, and other components of surgical instrument 102. Additionally, in some implementations, memory 1206 or a portion thereof may be incorporated into processor 1204.

[0054] Position sensor 1210 may be embodied as any type of sensor or sensing device or combination thereof capable of generating sensor data indicating the current state of jaw assembly 122 (e.g., whether jaw assembly 122 is closed or open). For example, in some embodiments, position sensor 1210 may be embodied as a sensor coupled to bracket 510 and configured to generate sensor data indicating the current position of bracket 510, which indicates the state of jaw assembly 122 as described above. In such embodiments, position sensor 1210 may be embodied as a Hall effect sensor, a mechanical switch sensor, and / or other sensors capable of detecting the relative position of bracket 510.

[0055] During operation, as described above, the controller 1202 is configured to control the activation of the clamping force enhancement system 600, thereby increasing the clamping force of the jaw assembly 122 of the end effector 120. To this end, the controller 1202 is configured to monitor sensor data generated by the position sensor 1210 to determine the current state of the jaw assembly 122. If the jaw assembly 122 is in the closed state and the RF mode of the surgical instrument is activated, the controller 1202 is configured to activate the clamping force enhancement system 600. As described above, when activated, the clamping force enhancement system 600 causes the holder 510 to move further in the proximal direction along the holder axis, thereby increasing the resulting clamping force of the jaw assembly 122 on the tissue captured by the jaw assembly 122. In doing so, the clamping force gears 610, 620 of the clamping force enhancement system 600 engage with each other to control the movement of the holder 510, as described above.

[0056] See now Figure 13A and Figure 13B In use, the controller 1202 of the surgical instrument 102 can be configured to perform a method 1300 for controlling the clamping force of the jaw assembly 122 of the end effector 120 during the RF mode of the surgical instrument. Method 1300 begins at block 1302, where the controller 1202 executes one or more initialization procedures. For example, the controller 1202 may verify the operation of the position sensor 1210, the clamping force enhancement system 600, and / or other initialization or verification procedures.

[0057] After controller 1202 has executed the initialization procedure in block 1304, method 1300 proceeds to block 1306, where controller 1202 monitors the actuation of jaw assembly 122. For this purpose, controller 1202 may monitor position data generated by position sensor 1210, which indicates the position of bracket 510 and thus indicates the activation or movement of jaw assembly 122. In block 1308, controller 1202 determines whether jaw assembly 122 has moved to a closed state based on the position data received from position sensor 1210. Similarly, for this purpose, controller 1202 may determine whether bracket 510 is located at a position associated with the closed position of jaw assembly 122 as indicated by the position data from position sensor 1210. If the jaw assembly is not in the closed position, method 1300 loops back to block 1306, where controller 1202 continues to monitor the sensor for actuation of jaw assembly 122.

[0058] However, if controller 1202 determines that jaw assembly 122 is in the closed state, method 1300 proceeds to block 1310, where controller 1202 determines whether the RF mode of surgical instrument 102 has been activated. If so, method 1300 proceeds to block 1312, where controller 1202 further monitors the position of bracket 510, as indicated by sensor data from position sensor 1210, and determines in block 1314 whether bracket 510 is in the full-stroke position. When bracket 510 is in the full-stroke position, jaw assembly is fully closed, and clamping force gears 610, 620 approach or contact each other, as described above. For example, in Figures 7 to 9 In the illustrated embodiment, the clamping force gear 610 of the clamping force motor 602 can be received in the channel 700 of the bracket 510 such that when the bracket 510 is in its full-stroke position, the clamping force gears 610, 620 are in contact with each other. If the bracket 510 is not in its full-stroke position, method 1300 cycles back to block 1312, where the controller 1202 continues to monitor the position of the bracket 510.

[0059] However, if controller 1202 determines that bracket 510 has moved to its full travel position, method 1300 proceeds to block 1316. In block 1316, controller 1202 activates clamping force enhancement system 600. In doing so, in block 1318, controller 1202 activates and controls the operation of clamping force motor 602. In block 1320, activation of clamping force motor 602 causes clamping force gear 610 of clamping force motor 602 to engage or mesh with clamping force gear 620 of bracket 510. The engagement of clamping force gears 610, 620, and further activation and control of clamping force motor 602, further cause bracket 510 to travel or move in the proximal direction along bracket axis 512, as... Figure 7 As indicated by arrow 750. As described above, further movement or travel of the bracket 510 along the bracket axis 512 increases the clamping force applied by the jaw assembly 122.

[0060] Subsequently, in box 1324, controller 1202 determines whether a reference clamping force has been achieved. Controller 1202 may determine the current clamping force based on the current position of bracket 510 and / or based on sensor data from force sensors, etc. Additionally, controller 1202 may adjust the reference clamping force based on various criteria, such as the type or model of the surgical instrument, the specific surgical procedure being performed, historical preference data, the current position of trigger assembly 150, and / or other criteria.

[0061] If controller 1202 determines that the reference clamping force has not yet been achieved, method 1300 loops back to block 1316, where controller 1202 continues to activate the clamping force enhancement system 600 to obtain the desired or reference clamping force for jaw assembly 122. However, if the reference clamping force has been achieved, method 1300 loops back to block 1306, where the controller continues to monitor the actuation of jaw assembly 122 as described above.

[0062] Referring again to box 1310, if controller 1302 determines in box 1308 that the jaw assembly is in the closed state, but the RF mode has not yet been activated in box 1310, then method 1300 proceeds to... Figure 13B Box 1326. In box 1326, controller 1202 determines whether the ultrasound mode of surgical instrument 102 has been activated. If not, method 1300 loops back to... Figure 13A In block 1306, controller 1202 continues to monitor actuation of jaw assembly 122. However, if controller 1202 determines that an ultrasonic mode has been activated, method 1300 proceeds to block 1328. In block 1328, controller 1202 deactivates clamping force enhancement system 600. To this end, in block 1330, controller 1202 controls clamping force motor 602 to disengage clamping force gear 610 of clamping force motor 602 from clamping force gear 620 of bracket 510. Additionally, in an embodiment where clamping force motor 602 moves during activation of clamping force enhancement system 600, in block 1332, clamping force motor 602 moves back to its original position. Method 1300 then cycles back to... Figure 13A In frame 1306, controller 1202 continues to monitor actuation of jaw assembly 122, as described above. In this way, controller 1202 is configured to control the increase in clamping force of jaw assembly 122 by selectively engaging and disengaging clamping force gears 610, 620 from each other.

[0063] Although the present disclosure has been illustrated and described in detail in the accompanying drawings and the foregoing description, such illustrations and descriptions should be regarded as exemplary rather than restrictive in nature, and it should be understood that only exemplary embodiments are shown and described, and all changes and modifications made within the substance of the present disclosure should be protected.

[0064] The methods, apparatus, and systems described herein possess numerous advantages due to their various features. It should be noted that alternative embodiments of the methods, apparatus, and systems of this disclosure may exclude all described features, but may still benefit from at least some of the advantages of such features. Those skilled in the art will readily conceive of their own implementations of the methods, apparatus, and systems described above, which may incorporate one or more features of the invention and fall within the spirit and scope of this disclosure as defined by the appended claims.

Claims

1. A surgical instrument, said surgical instrument comprising: An end effector having a jaw assembly movable between an open state and a closed state, wherein the jaw assembly includes an ultrasonic scalpel; A trigger assembly operable to move the jaw assembly of the end effector between an open state and a closed state, wherein the trigger assembly includes a position sensor configured to generate sensor data indicating the current state of the jaw assembly of the end effector; A clamping force enhancement system, which can be controlled to increase the clamping force of the jaw assembly of the end effector; A controller configured to control the activation of an ultrasonic mode and a radio frequency (RF) mode of the surgical instrument, wherein the controller is configured to activate the clamping force enhancement system in response to (i) the RF mode being activated and (ii) the position sensor indicating that the current state of the jaw assembly is in the closed state, to increase the clamping force of the jaw assembly of the end effector.

2. The surgical instrument according to claim 1, wherein, The trigger assembly includes a mode switch that can be selected to instruct the controller to activate the RF mode.

3. The surgical instrument according to claim 1, wherein, Activating the clamping force enhancement system includes engaging a first clamping force gear and a second clamping force gear of the clamping force enhancement system to increase the clamping force of the jaw assembly of the end effector.

4. The surgical instrument according to claim 3, wherein, The trigger assembly includes a bracket configured to move along a bracket axis in response to operation of the trigger assembly, thereby moving the jaw assembly of the end effector between the open state and the closed state. The clamping force enhancement system includes a clamping force motor, the clamping force motor includes a first clamping force gear, and the bracket includes a second clamping force gear.

5. The surgical instrument according to claim 3, wherein, The bracket includes a channel having an opening defined at a proximal end of the bracket, wherein the second clamping force gear is located within the channel.

6. The surgical instrument according to claim 5, wherein, The first clamping force gear of the clamping force motor is configured to be received within the channel of the bracket to engage with the second clamping force gear when the clamping force enhancement system is activated.

7. The surgical instrument of claim 6, further comprising a biasing spring connected to the bracket and the clamping force motor, the biasing spring being configured to bias the first clamping force gear away from the second clamping force gear along the axis of the bracket.

8. The surgical instrument of claim 4, wherein the second clamping force gear extends proximally away from the proximal end of the bracket.

9. The surgical instrument according to claim 8, wherein, The first clamping force gear is configured to engage axially with the second clamping force gear when the clamping force enhancement system is engaged.

10. The surgical instrument according to claim 4, wherein, The engagement of the first clamping force gear and the second clamping force gear causes the bracket to move toward the proximal side along the bracket axis.

11. The surgical instrument according to claim 1, wherein, The controller is configured to deactivate the clamping force enhancement system in response to (i) the activation of the ultrasonic mode or (ii) the position sensor indicating that the current state of the jaw assembly is not in the closed state.

12. A method for controlling the operation of a surgical instrument, the method comprising: The controller of the surgical instrument determines whether the jaw assembly of the end effector of the surgical instrument is in a closed state based on sensor data generated by the position sensor of the trigger assembly of the surgical instrument. The controller determines whether the radio frequency (RF) mode of the surgical instrument has been activated; as well as In response to determining (i) that the jaw assembly is in the closed state and (ii) that the RF mode has been activated, the controller activates the clamping force enhancement system of the surgical instrument to increase the clamping force of the jaw assembly of the end effector.

13. The method according to claim 1, wherein, Activating the clamping force enhancement system includes engaging a first clamping force gear and a second clamping force gear of the clamping force enhancement system to increase the clamping force of the jaw assembly of the end effector.

14. The method according to claim 13, wherein, Activating the clamping force enhancement system includes inserting the first clamping force gear into a channel defined in the proximal end of the bracket of the trigger assembly of the surgical instrument to engage the second clamping force gear located within the channel.

15. The method according to claim 14, wherein, Engaging the first clamping force gear with the second clamping force gear includes moving the bracket proximally along the bracket axis.

16. The method according to claim 13, wherein, Activating the clamping force enhancement system includes engaging the first clamping force gear with a second clamping force gear extending from the proximal end of the bracket of the trigger assembly of the surgical instrument.

17. The method according to claim 16, wherein, Engaging the first clamping force gear with the second clamping force gear includes axially meshing the first clamping force gear with the second clamping force gear.

18. The method of claim 12, further comprising, in response to (i) the controller determining that the RF mode has been disabled or (ii) the controller determining that the jaw assembly of the end effector is not in the closed state, disabling the clamping force enhancement system by the controller.

19. A surgical instrument, said surgical instrument comprising: An end effector having a jaw assembly movable between an open state and a closed state, wherein the jaw assembly includes an ultrasonic scalpel; A trigger assembly operable to move the jaw assembly of the end effector between an open state and a closed state, wherein the trigger assembly includes a position sensor and a bracket, the position sensor being configured to generate sensor data indicating the current state of the jaw assembly of the end effector, and the bracket being configured to move along a bracket axis in response to operation of the trigger assembly to move the jaw assembly of the end effector between the open state and the closed state; A clamping force enhancement system, which is controllable to increase the clamping force of the jaw assembly of the end effector, wherein the clamping force enhancement system includes a first clamping force gear connected to a clamping force motor and a second clamping force gear connected to the bracket; A controller configured to control the activation of a radio frequency (RF) mode of the surgical instrument, wherein the controller is configured to activate the clamping force enhancement system in response to determining (i) that the RF mode is activated and (ii) that the jaw assembly is in the closed state, so as to engage the first clamping force gear with the second clamping force gear.

20. The surgical instrument according to claim 19, wherein, The bracket includes a channel having an opening defined at a proximal end of the bracket, wherein the second clamping force gear is located within the channel. Engaging the first clamping force gear with the second clamping force gear includes receiving the first clamping force gear within the channel of the bracket.

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