Electrosurgical system for preventing reuse of instruments

Abstract

To provide an electrosurgical system for preventing reuse of instruments.SOLUTION: An electrosurgical generator configured to generate electrical energy to be applied to biological tissue via electrical communication with an electrosurgical instrument includes a power source configured to activate to output the electrical energy to the electrosurgical instrument, a measurement circuit configured to measure a resistive value associated with an erodible coating deposited on a portion of the electrosurgical instrument, and a control circuit configured to compare the measured resistive value of the erodible coating to a threshold resistive value of the coating, and control the activation of the power source based on the comparison between the measured resistive value and the threshold resistive value.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 227,510, filed July 30, 2021, and U.S. Provisional Patent Application No. 63 / 262,918, filed October 22, 2021, the contents of which are incorporated by reference in their entireties into this application.

[0002] This specification relates generally, but not exclusively, to electrosurgical systems and electrosurgical devices that may be used to create changes in living tissue. [Background technology]

[0003] Electrosurgery involves the application of electrical energy to the living tissue of a surgical patient, for example, to cut, coagulate, cauterize, desiccate, or discharge coagulate the living tissue. These electrosurgical techniques may be performed with a wide variety of surgical procedures, such as laparoscopic instruments, including, but not limited to, appendectomies, cholecystectomies, colectomies, cystectomies, gastric banding, gastric bypass, hernia repair, nephrectomies, Nissen fundoplications, prostatectomies, sleeve gastrectomies, or other procedures, among others. Furthermore, each of these procedures may include one or more phases, such as an interrogation phase, a heating phase, a desiccation phase, a cauterization phase, or other phases, that involve the application of electrical energy. The electrical energy used in such procedures may be generated by an electrosurgical generator and output to an electrosurgical instrument in electrical communication with the electrosurgical generator.

[0004] For example, various electrosurgical instruments may be removably connected to the electrosurgical generator, including, but not limited to, forceps, conductive spatulas, electric pads, laparoscopic loops, or cutting devices. Thus, the electrosurgical instruments may be configured to electrically and mechanically engage the biological tissue to which the electrical energy is delivered. In addition, different surgical procedures may implement different electrical energy applications to achieve results unique to the particular surgical procedure, such as by controlling or modifying one or more electrical metrics to produce an effective result on the biological tissue engaged by the electrosurgical instrument. The electrical metrics may be, but are not limited to, polarity (monopolar, bipolar), AC and / or DC, frequency, signal amplitude, attack and attenuation profile, or combinations thereof. Summary of the Invention [Means for solving the problem]

[0005] The electrosurgical generator is configured to generate electrical energy for application to biological tissue via electrical communication with an electrosurgical instrument, the electrosurgical generator comprising: a power source configured to operate to output the electrical energy to the electrosurgical instrument; a measurement circuit configured to measure a resistance value associated with an erodible coating deposited on a portion of the electrosurgical instrument; and a control circuit in communication with the power source and the measurement circuit, the control circuit configured to compare the measured resistance value of the erodible coating to a threshold resistance value for the coating and to control operation of the power source based on the comparison of the measured resistance value to the threshold resistance value. [Brief description of the drawings]

[0006] In the drawings, which are not necessarily to scale, the same numerals may describe similar components in different views. The same numerals with different letter suffixes may indicate different instances of similar components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document.

[0007] [Figure 1] 1 illustrates a perspective view of an exemplary electrosurgical system for delivering electrical energy to living tissue. [Diagram 2] 1 illustrates a block diagram of an exemplary electrosurgical system. [Diagram 3] 1 shows a schematic diagram of an exemplary output device of an electrosurgical generator. [Figure 4] 1A-1D illustrate an exemplary electrosurgical instrument including surgical jaws having a hydrophobic layer deposited thereon. [Diagram 5] 1A-1C illustrate an exemplary electrosurgical dissection forceps having a hydrophobic layer deposited thereon. [Figure 6] FIG. 1 illustrates an example of an electrosurgical pencil having a hydrophobic layer deposited thereon. [Figure 7] FIG. 1 illustrates an example of a distal portion of an electrosurgical laparoscope loop having a hydrophobic layer deposited thereon. [Figure 8] 1 shows a schematic diagram of an exemplary hydrophobic layer deposited on a surface of an electrosurgical device. [Figure 9] 1 shows a schematic diagram of an exemplary hydrophobic layer deposited on a surface of an electrosurgical device. [Figure 10] 1 shows an example of a laser etched surface having hydrophobic physical structures formed thereon. [Figure 11] 1 shows a flowchart of an exemplary method for preventing reuse of an electrosurgical instrument after a limit of the electrosurgical instrument has been exceeded. [Figure 12A] 1 shows a perspective view of an electrosurgical instrument having a hydrophobic layer deposited thereon. [Figure 12B] 1 shows a cross-sectional view of an electrosurgical instrument having a hydrophobic layer deposited thereon. [Figure 13] 1 shows an exemplary waveform illustrating electrical energy traveling through biological tissue. [Figure 14] 1 shows an exemplary graph illustrating an erosion curve of a hydrophobic layer as a function of application of electrical energy to the hydrophobic layer. [Figure 15]1 illustrates a flowchart of an exemplary method for controlling the output of electrical energy from an electrosurgical generator to an interconnected electrosurgical instrument based on the thickness of an erodible coating deposited on the electrosurgical instrument. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] The following description and drawings sufficiently illustrate specific examples to enable one skilled in the art to practice them. Other examples may incorporate structural, process, or other changes. Portions and features of some examples may be contained in or substituted for portions and features of other examples. Examples set forth in the claims encompass all available equivalents of those claims.

[0009] During electrosurgical procedures, coagulated fluids or solid tissue debris can accumulate on the electrosurgical instrument when electrical energy is applied to biological tissue using the electrosurgical instrument. The electrical energy is converted to heat as a function of the electrical resistance of various biological tissues, causing the fluid or solid tissue to adhere to parts of the electrosurgical instrument, such as the electrically assisted cutting or vessel sealing elements, or to the mechanical gripping components. This can impede various aspects of the electrosurgical procedure. For example, coagulation of fluid on the cutting element can increase surface adhesion, which can reduce the effectiveness of the cutting element and lead to tissue laceration. In another example, tissue accumulation on the electrodes can prevent the electrosurgical instrument from effectively sealing blood vessels. In a further example, blood or tissue accumulation on any moving components of the electrosurgical instrument, such as the jaws of a pivoting forceps or an expanding blade, can impair effective user operation or use and prolong the electrosurgical procedure.

[0010] To help address these issues, among others, hydrophobic layers may be deposited on various components of the electrosurgical instrument. For example, the hydrophobic layer may include or define various coatings, surface structures, or combinations thereof to reduce surface adhesion of the electrosurgical instrument. For example, the hydrophobic layer may function as an anti-stick layer and include a polysiloxane or fluorosilane nanocoating, or an etched surface that forms or provides various nanostructures. However, during normal use of the electrosurgical instrument, the anti-stick layer may be damaged by electrical energy received by the electrosurgical instrument, such as from an electrosurgical generator. For example, the hydrophobic layer may erode or otherwise degrade each time the electrosurgical generator outputs electrical energy to the electrosurgical instrument. Eventually, for example, within a single electrosurgical procedure, the hydrophobic layer may erode to a point where it no longer reduces surface adhesion of the electrosurgical instrument.

[0011] In this manner, the operational limit or lifespan of the hydrophobic layer may be quantified by the number of electrical energy signals that the electrosurgical generator outputs to the electrosurgical instrument. For example, the electrical energy used may be an intermittent or periodic signal that is output to the electrosurgical instrument upon individual or separate activations of the electrosurgical generator's power source. Furthermore, many electrosurgical instruments are configured to be discarded for various reasons after use in a surgical procedure, such as, but not limited to, difficulties with effectively sterilizing the instrument, expected erosion of the instrument's hydrophobic layer, expected wear of stationary or moving components of the instrument, or a combination thereof. Thus, problems may arise if the instrument is reprocessed and reused in a subsequent electrosurgical procedure without taking appropriate precautions. For example, a reprocessed instrument may have reduced functionality or may lead to patient infection if not effectively sterilized. As a result, an electrosurgical system is desired that can block or otherwise prevent the use of an electrosurgical instrument after a predetermined limit or useful lifespan of the electrosurgical instrument has been exceeded or has expired.

[0012] The present disclosure may help address these problems, among other things, by providing an electrosurgical system capable of identifying and monitoring predetermined limitations of various electrosurgical instruments. The electrosurgical generator may include control circuitry configured to identify predetermined limitations (e.g., useful life) of electrosurgical instruments in electrical communication with the electrosurgical generator. For example, during an electrosurgical procedure, the control circuitry may count, tally, and / or store the number of electrical energy signals output to electrosurgical instruments in electrical communication with the electrosurgical generator, e.g., by controlling or otherwise monitoring the power (e.g., electrical energy) source of the electrosurgical generator.

[0013] The electrosurgical system may also inform the user of the remaining useful life of the electrosurgical instrument in real time during the procedure by comparing the counting, tabulating, and / or stored number of electrical energy signals output to the electrosurgical instrument with a predetermined limit (e.g., useful life), and may, for example, subsequently block or otherwise prevent the electrosurgical generator power source from outputting electrical energy when the predetermined limit of the electrosurgical instrument is exceeded. Additionally, the control circuitry may block or otherwise prevent reprocessing and reuse of various disposable electrosurgical instruments after a predetermined limit is exceeded, such as by storing data on the electrosurgical instrument or in an electrosurgical device that includes or is associated with the electrosurgical instrument. For example, such data may be readable by another electrosurgical generator to prevent or otherwise prevent the electrosurgical generator from outputting electrical energy to the expired electrosurgical instrument in a subsequent procedure.

[0014] Although the above overview describes examples generally related to non-stick coatings used in electrosurgical instruments, the following system, device, or method description may be applicable to other coatings in other applications, such as for purposes other than reducing friction or surface adhesion, or to extend the life of various electrosurgical instrument components. The above overview is intended to provide an overview of the subject matter of the present patent application. It is not intended to provide an exclusive or exhaustive description of the invention. The following description is included to provide further information regarding the present patent application.

[0015] FIG. 1 illustrates a perspective view of an exemplary electrosurgical system 100 for delivering electrical energy to biological tissue 102. FIG. 1 also illustrates a central axis A1. The electrosurgical system 100 may include an electrosurgical generator 104 and an electrosurgical device 106. The electrosurgical generator 104 is configured to generate electrical energy and may include, for example, a user-operably disposed power source and output the electrical energy to the electrosurgical device 106. The electrosurgical device 106 may include an electrosurgical instrument 108. The electrosurgical instrument 108 may be any of a variety of electrosurgical end effectors configured to engage the biological tissue 102 in any of a variety of ways, including, for example, but not limited to, applying electrical energy to the biological tissue 102 by touching or direct contact with the biological tissue 102.

[0016] For example, as shown in FIG. 1 , the electrosurgical instrument 108 may be an electrosurgical forceps including a first jaw 110 and a second jaw 112. The first jaw 110 and the second jaw 112 may be configured to clamp, grasp, or otherwise hold a portion of the biological tissue 102 therebetween, for example, to pass electrical energy to any portion of the biological tissue 102 located between the first jaw 110 and the second jaw 112. Other electrosurgical instruments may engage the biological tissue 102 in other manners. For example, other types of electrosurgical instruments 108 may apply electrical energy to the biological tissue 102 in a manner that includes, but is not limited to, clamping, cutting, radiating, surrounding, or penetrating the biological tissue 102.

[0017] The electrosurgical device 106 may further include a hand piece 114 and a shaft assembly 116. The hand piece 114 may include a handle 118, a gripping lever 120, a cutting trigger 122, an energy button 124, and a rotation wheel 126. The shaft assembly 116 may include a proximal portion 128 and a distal portion 130. The proximal portion 128 may be connected to the hand piece 114 and the distal portion 130 may be connected to the electrosurgical instrument 108. The shaft assembly 116 may extend longitudinally from the hand piece 114 and distally to define a central axis A1. The shaft assembly 116 allows a portion of the electrosurgical device 106 (e.g., the electrosurgical instrument 108) to be inserted into the anatomy of a patient while allowing a remaining portion of the electrosurgical device 106 (e.g., the hand piece 114 and the proximal portion 128 of the shaft assembly 116) to remain outside of the patient. The shaft assembly 116 may include various conductive elements (e.g., wires, a conductive outer shaft, and / or a conductive inner shaft, etc.) that extend between the electrosurgical instrument 108 and any element or component of the handpiece 114 to enable electrical communication between the electrosurgical generator 104 and the electrosurgical instrument 108.

[0018] In some examples, the electrosurgical instrument 108 removably engages the shaft assembly 116, e.g., can be removed and discarded after completion of the electrosurgical procedure. In another example, the electrosurgical instrument 108 can be fixedly engaged or integrally formed with the shaft assembly 116. In such examples, the entire electrosurgical device 106, including the shaft assembly 116 and hand piece 114, can be discarded after completion of the electrosurgical procedure. Thus, the terms "electrosurgical device 106" and "electrosurgical instrument 108" can be used interchangeably in any examples described below, at least as used in conjunction with the terms "predetermined limit" and "useful life." The shaft assembly 116 can include an elongated hollow member (e.g., a tubular outer shaft) that encloses the cutting element 132 and a mechanical linkage that operably couples the cutting element 132 to the cutting trigger 122. For example, the cutting element 132 can be a blade that is slidable or otherwise actuable along a central axis A1. The cutting element 132 may cut, ablate, or otherwise affect the living tissue 102 or any object located between the first jaw 110 and the second jaw 112 of the electrosurgical instrument 108 .

[0019] The gripping lever 120, the cutting trigger 122, the energy button 124, and the rotation wheel 126 of the handpiece 114 are each configured to cause various actuations of the shaft assembly 116. The gripping lever 120 may be an actuator operably coupled to the electrosurgical instrument 108, for example, via a mechanical linkage disposed within the shaft assembly 116, such that the gripping lever 120 may be movable from an open position (shown in FIG. 1 ) to a closed position in which the gripping lever 120 is moved proximally toward the handle 118 and the first jaw 110 or the second jaw 112 is pivoted to contact or otherwise engage the biological tissue 102. The cutting trigger 122 may be an actuator operably coupled to a cutting element 132 disposed on a distal portion 130 of the shaft assembly 116, for example, via a mechanical linkage extending within the shaft assembly 116. This allows the cutting trigger 122 to be movable from a retracted position (as shown in FIG. 1) to an deployed position, where the cutting trigger 122 is moved proximally toward the handle 118, causing the cutting element 132 to cut any portion of the biological tissue 102 located between the first jaw 110 and the second jaw 112 of the electrosurgical instrument 108.

[0020] The rotation wheel 126 is an operable adjustment feature that may adjust the orientation or position of either the shaft assembly 116, the cutting element 132, the first jaw 110, or the second jaw 112 relative to one another, for example, about a central axis A1. Rotation of the rotation wheel 126 about the central axis A1 may cause either the shaft assembly 116, the cutting element 132, the first jaw 110, or the second jaw 112 to rotate about the central axis A1 and translate laterally relative to one another. The energy button 124 may be an input device or feature configured to activate a power (e.g., electrical energy) source of the electrosurgical generator 104 to output electrical energy to the electrosurgical device 106. The energy button 124 may thereby cause the electrosurgical generator 104 to output electrical energy to the electrosurgical instrument 108, such as one or more electrodes disposed on either the first jaw 110 or the second jaw 112, the cutting element 132, a remote electrode pad, or various other elements or components of the electrosurgical instrument, to cauterize, seal, or otherwise electrically affect the living tissue 102. Detailed examples of electrosurgical devices are shown and described in U.S. Patent Application Publication No. 2020 / 0305960, the entire contents of which are incorporated herein by reference. Additionally, detailed examples of electrosurgical systems are shown and described in WO 2020 / 227519, the entire contents of which are incorporated herein by reference.

[0021] Electrosurgical system 100 may include control circuitry 134 (shown diagrammatically in FIG. 1). Control circuitry 134 may be integrated into electrosurgical generator 104 or may be implemented as a stand-alone external device or controller in electrical communication with electrosurgical generator 104 and electrosurgical device 106. For example, control circuitry 134 may be in direct (e.g., wired) or wireless (e.g., network) connection with electrosurgical generator 104 and electrosurgical device 106. Control circuitry 134 may control, or transfer data to, and receive data from, various components of electrosurgical system 100. For example, control circuitry 134 may control a power source for electrosurgical generator 104, e.g., activate the power source to output electrical energy to electrosurgical instrument 108. Control circuitry 134 may also count, tally, and store each actuation, including the length (e.g., time span) of each actuation, etc., in various memory elements or components of electrosurgical system 100, etc.

[0022] The electrosurgical generator 104 may include a user interface 136, including, for example, various input and output devices. For example, the user interface 136 may include a visual display, such as a touch screen, or may include any of a variety of gauges, dials, buttons, switches, or lights. In some examples, the electrosurgical generator 104 may be coupled to an external input device, such as a keyboard or mouse, or an external output device, such as a remote display screen. The control circuitry 134 is in electrical communication with the user interface 136 and may control various functions or operations of the electrosurgical generator 104. For example, parameters or electrical metrics of the electrical energy output by the power source of the electrosurgical generator 104 are configured via inputs to the user interface 136, such as, for example, the electrical energy is configured to resistively heat the biological tissue 102 to cauterize and seal blood vessels.

[0023] The electrosurgical system 100 may include an electrical connector 138. The electrical connector 138 may removably connect the electrosurgical generator 104 to the electrosurgical device 106 to establish electrical communication therebetween. For example, the electrical connector 138 may be any of a variety of electrical connectors suitable for transferring radio frequency (RF) energy from the electrosurgical generator 104 to the electrosurgical device 106. In some examples, the electrical connector 138 may be a component of the electrosurgical device 106, such as one configured to engage an instrument interface associated with the electrosurgical generator 104. In another example, the electrical connector 138 may be implemented between two separate electrical connectors, such as a male connector associated with the electrosurgical device 106 and a female connector associated with the electrosurgical generator 104, or vice versa.

[0024] The electrical connector 138 may also establish a data link between the electrosurgical generator 104 and the electrosurgical device 106. For example, the control circuit 134 of the electrosurgical generator 104 may be configured to transfer data to or receive data from the memory of the electrosurgical device 106 by establishing an electrical connection therebetween, for example, to identify a predetermined limit (e.g., useful life) of the electrosurgical device 106 connected to the electrosurgical generator 104. The electrosurgical instrument 108 may include a hydrophobic layer 140. The hydrophobic layer 140 may be a coating, a surface structure, or a combination thereof, such as a material configured to act as a non-stick layer by reducing surface adhesion between the surface of the electrosurgical instrument 108 and the surface of the biological tissue 102. For example, as shown in FIG. 1, the hydrophobic layer 140 may be deposited or otherwise formed on any of a variety of surfaces of the first jaw 110, the second jaw 112, the cutting element 132, or the interior surface of the shaft assembly 116 to which the cutting element 132 belongs.

[0025] In some examples, the hydrophobic layer 140 may define a predetermined limit (e.g., useful life) of the electrosurgical instrument 108. In such examples, the hydrophobic layer 140 may erode or linearly degrade as a function of normal electrosurgical use, for example decreasing slightly in thickness each time the power source of the electrosurgical generator 104 is activated to output electrical energy to the electrosurgical instrument 108 or over an active period during which the power source is otherwise outputting electrical energy to the electrosurgical instrument 108. In some examples, the predetermined limit of the electrosurgical instrument 108 may be quantified as the total (e.g., total) number of power source activations or the total (e.g., total) active period before the hydrophobic layer 140 is found to fail or no longer effectively reduce surface adhesion between the electrosurgical instrument 108 and the biological tissue 102. In some examples, the predetermined limit can be an effective time window, e.g., a period of time (such as hours or minutes), during which the electrosurgical procedure begins after a first engagement or connection of the electrosurgical instrument 108 to the electrosurgical mover 104, or begins and is completed after a first disengagement or disconnection of the electrosurgical instrument 108 from the electrosurgical mover 104. This allows the electrosurgical system 100 to identify and monitor (e.g., track) the predetermined limit of the electrosurgical instrument 108 during preparation for or during the electrosurgical procedure.

[0026] The electrosurgical system 100 may further prevent use of the electrosurgical device 106 when a predetermined limit of the electrosurgical instrument 108 is exceeded. For example, the control circuitry 134 may count, tally, and store the number and length of power source activations output to the electrosurgical instrument 108 so that the control circuitry 134 can recognize when a predetermined limit of the electrosurgical instrument 108 has been exceeded and, in response, the control circuitry 134 may prevent activation of the power source, such as until another (e.g., unexpired) electrosurgical instrument 108 is connected to the electrosurgical generator 104. Additionally, if a predetermined limit of the electrosurgical instrument 108 has been exceeded, the control circuitry 134 may transfer data to a memory of the electrosurgical device 106 or the electrosurgical instrument 108, configured to prevent subsequent reuse of the electrosurgical instrument 108 after the electrosurgical procedure has concluded, for example. For example, if the electrosurgical instrument 108 is later reprocessed and coupled to a different electrosurgical generator, the control circuit 134 may receive (e.g., read) the stored data and prevent the power source from activating and preventing electrical energy from being output to the electrosurgical instrument 108.

[0027] In some example operation of the electrosurgical system 100, a user may first connect the electrosurgical device 106 to the electrosurgical generator 104, for example, using the electrical connector 138. The electrosurgical generator 104 may then interact with the electrosurgical device 106, for example recognizing a predetermined limit of the electrosurgical instrument 108. The user may then apply electrical energy to the biological tissue 102, for example, by operating the energy button 124 of the electrosurgical device 106 while the electrosurgical instrument 108 is in contact with or otherwise engaged with the biological tissue 102. The control circuitry 134 may simultaneously count and tally each actuation of the power source on a memory of the electrosurgical generator 104 or electrosurgical device 106, including, for example, the length of each actuation. Finally, upon recognizing that a predetermined limit has been exceeded, the control circuitry 134 may prevent the power source from being actuated and prevent the output of electrical energy to the electrosurgical device 108. In yet another example, the control circuit 134 can enable the application of electrical energy to the biological tissue 102 after a predetermined limit of the electrosurgical instrument 108 has been exceeded, provided, for example, that the electrosurgical instrument 108 has not been disconnected from the electrosurgical generator 104 or has not been disconnected from the electrosurgical generator 104 for a period of time that exceeds a predetermined effective time window as measured by a clock or timer in the control circuit 134.

[0028] Electrosurgical system 100 may thereby provide various benefits to both the user and the patient during an electrosurgical procedure. For example, electrosurgical system 100 may identify and monitor predetermined limits of a disposable electrosurgical instrument or device, e.g., to prevent a user from inadvertently exceeding the useful life of an electrosurgical instrument during an electrosurgical procedure. This may help improve patient outcomes in various electrosurgical procedures by preventing tissue lacerations or incomplete vessel sealing caused, for example, by failure of a hydrophobic layer (e.g., a non-stick coating) deposited thereon due to adherent tissue interfering with the operation of the device. Electrosurgical system 100 may also prevent reuse of an expired electrosurgical instrument after a predetermined limit (e.g., useful life) of the electrosurgical instrument has been exceeded. This may help reduce post-operative patient infections due to insufficient sterilization of a reprocessed electrosurgical instrument and prevent patient trauma caused by reduced functionality of a reprocessed electrosurgical instrument, e.g., where such reduced functionality may be difficult or impossible to ascertain prior to engaging an anatomical structure with an expired electrosurgical instrument.

[0029] FIGURE 2 shows a block diagram of an exemplary electrosurgical system 100. FIGURE 2 will be described with reference to the electrosurgical system 100 shown in and described above with respect to FIGURE 1. In some examples, electrosurgical system 100 may be implemented using the elements shown in FIGURE 2. In other examples, electrosurgical system 100 may include various other elements. As shown in FIGURE 2, electrosurgical generator 104 may include a user interface 136, an instrument interface 142, a power source 144, and measurement circuitry 146, and electrosurgical device 106 may include an electrosurgical instrument 108 and a memory 148. Memory 148 may be located on or within any of the various components of electrosurgical device 106, including, but not limited to, electrosurgical instrument 108, electrical connector 138, or instrument interface 142. Thus, the terms "electrosurgical device 106" and "electrosurgical instrument 108" may be used interchangeably in any examples described below, as well as at least the terms "memory 148" and the terms "predetermined limit" and "useful life" used in connection with the terms "memory 148" and "predetermined limit" and "useful life" for the reasons discussed above.

[0030] In some examples, the control circuitry 134 may be an element contained or otherwise integrated within the electrosurgical generator 104. In another example, the control circuitry 134 is realized using a combination of elements from the electrosurgical generator 104 and the electrosurgical device 106. In yet another example, the control circuitry 134 may be a standalone control device located external to and in electrical communication with the electrosurgical generator 104 and the electrosurgical device 106. The control circuitry 134 may be in wired (e.g., direct) communication with the electrosurgical generator 104. Additionally or alternatively, the control circuitry 134 may be in wireless (e.g., network) communication with the electrosurgical generator 104, for example, transmitting and receiving data via near field communication (NFC), Bluetooth® (such as Bluetooth low energy), Wi-Fi, 3GPP® LTE, or other healthcare compliant wireless communication protocols.

[0031] The control circuitry 134 may include at least a processor 150 and a memory 152. In some examples, the processor 150 may include a timer and / or a clock. In other examples, the timer and / or clock may be separate elements from the processor 150 or may be included in a device separate from the processor 150. The processor 150 may include a hardware processor, such as a central processing unit (CPU), a graphics processing unit (GPU), a hardware processor core, or any combination thereof. The processor 150 may include any one or more of a microprocessor, a control circuit, a digital signal processor (DSP), an application specific integrated circuit (ASIC), a field programmable gate array (FPGA), or other equivalent discrete or integrated logic circuitry.

[0032] Thus, processor 150 may receive, retrieve, and / or process program instructions as stored on memory 152 (e.g., on program memory 152P) or may receive, retrieve, and / or process data stored on memory 152 (e.g., on data memory 152D) or on memory 148 (e.g., on data memory 148D) to implement or otherwise perform any of the various functions or operations of electrosurgical system 100 described in, without limitation, the following examples. In some examples, processor 150 may receive, retrieve, and / or process instructions or data to activate or deactivate power source 144. When activated, power source 144 may generate and output electrical energy and when deactivated, may cease generating and outputting electrical energy. In some examples, processor 150 may receive, retrieve, and / or process instructions or data to repeatedly activate and deactivate power source 144 to output variable electrical energy intermittently, periodically, cyclically, or otherwise.

[0033] In some examples, processor 150 may receive, retrieve, and / or process instructions or data to cause processor 150 to match or otherwise associate electrosurgical instrument 108 in electrical communication with electrosurgical generator 104 with data located in memory 148 and / or 152. For example, memory 152 may include identification data associated with electrosurgical instrument 108, and memory 148 may include thereon or be in network communication with a library (e.g., database) of information associated with various different electrosurgical instruments (such as, but not limited to, those shown in FIGS. 4-7 ) and their respective predetermined limitations. In such examples, processor 150 may receive, retrieve, and / or process instructions or data to initially connect electrosurgical instrument 108 to electrosurgical generator 104, causing processor 150 to obtain the identification data from memory 152 of electrosurgical instrument 108. Processor 150 may then receive, retrieve, and / or process instructions or data to retrieve an individual data set (e.g., a database entry) that defines or otherwise includes the predetermined limits of electrosurgical device 108 by matching the identification data of electrosurgical instrument 108 with associated data stored in memory 148. In another example, processor 150 may receive, retrieve, and / or process instructions or data to cause processor 150 to retrieve the predetermined limits of electrosurgical instrument 108 directly from memory 152 of electrosurgical instrument 108. Thus, control circuitry 134 may be configured to read information from electrosurgical instrument 108, identify or recognize the type or class of instrument to which electrosurgical instrument 108 belongs, and accordingly recognize, for example, a maximum total number of activations of power source 144, or a maximum active period, such that electrosurgical instrument 108 can receive the output of electrical energy to electrosurgical instrument 108 until inhibited or otherwise prevented by control circuitry 134.

[0034] In some examples, the processor 150 may receive, retrieve, and / or process instructions or data to count or record each successive actuation of the generator 144 and store, such as on memory 148 or 152, a total number (e.g., a sum) of power source actuations associated with an individual electrosurgical instrument 108. In some examples, the processor 150 may receive, retrieve, and / or process instructions or data to count or record the length (e.g., a timespan) of each successive actuation of the generator 144 and store, such as on memory 148 or 152, a total (e.g., a sum) active period of the electrosurgical instrument 108. In some examples, the processor 150 may receive, retrieve, and / or process instructions or data to delete the stored total number from memory 152, for example, upon disconnecting the electrosurgical instrument 108 from the electrosurgical generator 104. In some examples, processor 150 may receive, retrieve, and / or process instructions or data to continuously (e.g., in real time) or periodically compare the stored total number of times to a predetermined limit for electrosurgical instrument 108. In some examples, processor 150 may receive, retrieve, and / or process instructions or data to disable power source 144, for example, by interrupting signal communication between any input devices of electrosurgical system 100, such as between electrosurgical device 106 or user interface 136 and power source 144.

[0035] In some examples, the predetermined limit may be a maximum number of power actuations that can be received by the electrosurgical instrument 108. In such examples, the maximum number of power actuations may be less than, equal to, or greater than the total number of power actuations at which the hydrophobic layer 140 fails or the surface adhesion between the electrosurgical instrument 108 and the biological tissue 102 is no longer reduced. In another example, the predetermined limit of the electrosurgical instrument 108 may be less than, equal to, or greater than the total number of power actuations received by the electrosurgical instrument 108 at which the electrosurgical device 106 or other coatings or components of the electrosurgical instrument 108 fail or are presumed to be non-functional or indicate degraded or reduced functionality. In some examples, the predetermined limit may be a maximum active period of the electrosurgical instrument 108. In such examples, the maximum active period may be less than, equal to, or greater than the total (e.g., combined) active period at which the hydrophobic layer 140 fails or no longer reduces the surface adhesion between the electrosurgical instrument 108 and the biological tissue 102. In another example, the predetermined limit of the electrosurgical instrument 108 may be less than, equal to, or greater than the total active period at which the electrosurgical device 106 or other coatings or components of the electrosurgical instrument 108 fail or are presumed to be non-functional or exhibit degraded or reduced functionality.

[0036] In some examples, the predetermined limit may alternatively be, or may additionally include, an effective time window after a first engagement or connection of the electrosurgical instrument 108 to the electrosurgical generator 104, after which the predetermined limit is exceeded. In some examples, the predetermined limit may be a period of time, such as an effective time window after a first disengagement or disconnection of the electrosurgical device 106 or electrosurgical instrument 108 from the electrosurgical generator 104, after which the predetermined limit is exceeded. In such examples, the effective time window may be, or may additionally include, without limitation, a period of time that is less than, equal to, or greater than the number of hours or minutes that the surgical procedure is completed. For example, the effective time window may be, without limitation, about 1-60 minutes, 2-5 hours, or 6-12 hours. In yet other examples, the predetermined limit may include any combination of the exemplary predetermined limits above, including, for example, two or more of a maximum number of power activations, a maximum active period, or an effective time window. In such instances, the predetermined limit may be exceeded based on any or all of the example predetermined limits. With the above in mind, the terms "exceed" or "exceeding" may generally refer to any threshold value set below, at, or above any of the example predetermined limits above.

[0037] In some examples, processor 150 may receive, retrieve, and / or process instructions or data to operate generator 144 to generate and output electrical energy according to a predetermined electrical treatment schedule retrieved from memory 148 or 152, including by various electrical parameters or measurement metrics that define the electrical energy output to a particular electrosurgical instrument for a particular electrosurgical procedure or technique. Measurement circuitry 146 may be configured to measure one or more electrical parameters of biological tissue 102 engaged by electrosurgical instrument 108, or the electrical energy output by generator 144, such as by sensing either a current, voltage, or phase value with a sensor or other conductive component of electrosurgical instrument 108.

[0038] In some examples, processor 150 may further receive, retrieve, and / or process instructions or data to compare any electrical parameters or measurement metrics measured by measurement circuit 146 to a predetermined electrical treatment schedule. In response, processor 150 may receive, retrieve, and / or process instructions or data to execute commands to generator 144 and / or measurement circuit 146 to, for example, modify a parameter or metric of the electrical energy output by generator 144 to conform to the electrical treatment schedule, such as to achieve a desired electrosurgical result. In some examples, processor 150 may receive, retrieve, and / or process instructions or data to activate or repeatedly activate generator 144 upon one or more user inputs to electrosurgical device 106 or electrosurgical generator 104, such as upon operation of energy button 124 of electrosurgical device 106. In some examples, processor 150 may receive, retrieve, and / or process instructions or data to block or otherwise prevent activation or repeated activation of generator 144 upon one or more user inputs to electrosurgical device 106 or electrosurgical generator 104, such as by operating energy button 124 of electrosurgical device 106 after processor 150 has stored (in memory 148 or 152) a predetermined maximum number of power source activations (e.g., electrical energy outputs) receivable by electrosurgical instrument 108. For example, processor 150 may receive, retrieve, and / or process instructions or data to interrupt signal communication between electrosurgical device 106 and power source 144 to block or otherwise prevent activation of energy button 124 from causing activation of power source 144. In some examples, processor 150 may block or otherwise prevent activation of power source 144 until another (e.g., unexpired) electrosurgical instrument 108 is connected to electrosurgical generator 104.

[0039] In some examples, processor 150 may receive, retrieve, and / or process instructions or data to activate or repeatedly activate power source 144 after processor 150 has blocked or otherwise prevented power source 144 from activating in response to storing a maximum number of power source activations receivable by electrosurgical instrument 108 or a maximum active period of electrosurgical instrument 108. In some such examples, processor 150 may receive, retrieve, and / or process instructions or data to determine whether electrosurgical device 106 or electrosurgical instrument has previously been disconnected or otherwise disengaged from instrument interface 142 and / or electrical connector 138, for example, after a first engagement or connection with electrosurgical generator 104. In another such example, processor 150 may receive, retrieve, and / or process instructions or data to determine whether a valid time window has been exceeded or otherwise passed.

[0040] In response to processor 150 determining that electrosurgical device 106 or electrosurgical instrument 108 has not been previously detached or disengaged or that the validity window has not yet expired, processor 150 may receive, retrieve, and / or process instructions or data to re-enable operation of generator 144, for example, to output electrical energy to electrosurgical device 106 upon user operation of energy button 124, after a predetermined limit of the electrosurgical instrument 108 coupled to electrosurgical device 106 has been exceeded. This may, for example, prevent reuse of an expired electrosurgical instrument after an electrosurgical procedure has concluded, while at the same time allowing a user to continue to apply electrical energy to tissue in situations where a replacement instrument is not readily available or in-procedure replacement of the instrument is difficult or impractical.

[0041] In some examples, as noted above, the predetermined limit may alternatively be or additionally include a period of time, such as a maximum effective time window beginning after a first engagement or connection of the electrosurgical instrument 108 to the electrosurgical generator 104, or beginning after a first disconnection or disengagement of the electrosurgical instrument 108 from the electrosurgical generator 104. In such examples, such as upon a second engagement or reconnection of the electrosurgical instrument 108 to the electrosurgical generator 104 and thereby to the control circuit 134, the processor 150 may receive, retrieve, and / or process instructions or data to determine whether the reconnection or second engagement occurred within the maximum effective time window. For example, it may be desirable to disconnect or reconnect the electrosurgical instrument 108 during a procedure, such as to restart the electrosurgical generator 104, to move the electrosurgical device 106 to another connection port on the electrosurgical generator 104, or to temporarily utilize a different electrosurgical instrument. In response to the processor 150 determining that the electrosurgical instrument 108 has been reconnected or reengaged within the maximum effective time window, the processor 150 may receive, retrieve, and / or process instructions or data to re-enable operation of the power source 144, for example, to output electrical energy to the electrosurgical device 106.

[0042] The user interface 136 may communicate or transfer information between the electrosurgical system 100 and a user (e.g., a surgeon or technician). For example, the user interface 136 may include input / output devices, such as various displays, audible signal generators, switches, buttons, touch screens, mice, keyboards, and the like. The user interface 136 may include a communications module, such as with or in addition to any of the various input / output devices. The user interface 136 may utilize the communications module to communicate, for example, with external devices over one or more networks, such as one or more wireless or wired networks, or both. The communications module may include a network interface card, such as an Ethernet card, an optical transceiver, a radio frequency transceiver, or any other type of device capable of transmitting and receiving information. Other examples of such network interfaces include Bluetooth, 3G, 4G, Wi-Fi wireless computing devices, and universal serial bus (USB) devices. In some examples, the user interface 136 may include an output device 200, shown in FIG. 3 and described below with respect thereto.

[0043] In some examples, the processor 150 may receive, retrieve, and / or process instructions or data to implement selective user control over the power source 144, for example, to enable user configuration of parameters or metrics of the electrical energy generated and output by the power source 144 upon activation of the power source 144 via input to the user interface 136. In some examples, the processor 150 may receive, retrieve, and / or process instructions or data to cause the user interface 136 to generate and output an audible or visual alert to the user. In such examples, the audible or visual alert may correspond to a predetermined or user-selectable total number of power source actuations stored by the processor 150 and may, for example, provide the user with an indication of the remaining useful life of the electrosurgical instrument 108 before a maximum number of power source actuations (which defines a predetermined limit for the electrosurgical device 106 or electrosurgical instrument 108) is exceeded, or provide the user with an indication that a predetermined limit has been exceeded.

[0044] In some examples, the control circuit 134 may be in electrical communication with an output circuit of the electrosurgical generator 104. The output circuit may be configured to enable transfer of electrical energy generated by operation of the power source 144 to be output to the electrosurgical device 106. For example, the output circuit may be realized in the form of the power source 144 and an instrument interface 142. The instrument interface 142 may include any of a variety of signal drivers, buffers, amplifiers, or ESD protection devices, or output terminals such as engageable by the electrical connector 138. For example, the instrument interface 142 may be engaged directly or indirectly by elements or components of the electrosurgical device 106 or the electrical connector 138 to enable transfer of electrosurgical energy, such as radio frequency (RF) energy, to the biological tissue 102 via the electrosurgical instrument 108.

[0045] In an additional example, the electrosurgical system 100 may include wireless communication circuitry to enable wireless electrical communication between the control circuitry 134 and the electrosurgical device 106 or electrosurgical instrument 108. For example, the wireless communication circuitry may be embodied on or in the control circuitry, e.g., a generator component 154 located on or within the electrosurgical generator 104 in some examples, and an equipment component 156 located on or within the electrosurgical device 106 or electrosurgical instrument 108. As shown in FIG. 2, the generator component 154 may be, for example, but not limited to, a radio frequency identification (RFID) or near field communication (NFC) wireless transceiver, and the equipment component 156 may be, for example, but not limited to, a tag including an antenna 158 and a memory such as memory 148. For example, the equipment component 156 may be a radio frequency identification (RFID) or near field communication (NFC) passive inlay or hard tag, and may be made from any of a variety of materials, for example, including but not limited to, metal, plastic, or composite materials.

[0046] In some examples, the equipment component 156 may be an active tag, including a battery or other power source implemented separately from the electrosurgical generator 104, for example. In operation of such examples, the processor 150 may receive, retrieve, and / or process instructions or data to cause the transceiver to wirelessly receive or transmit data to the memory 148 using any of a variety of wireless protocols. In some examples, the generator component 154 may be configured to transmit or receive data to the memory 152 from a range of, but not limited to, about 1-10 centimeters, 0.1-1 meter, or 1-30 meters. The receiving or transmitting range of the generator component 154 may depend on the frequency or wavelength of the tagging of the equipment component 156, for example, very high frequency (VHF), extremely high frequency (UHF), short wave (HF), or long wave (LF).

[0047] In some examples, memory 148 or 152 may be used by software or applications executing on electrosurgical generator 104 or control circuitry 134 to store various program instructions for execution by processor 150 to perform, for example, but not limited to, any of the functions or operations of electrosurgical system 100 described above. In some examples, memory 148 or 152 may be described as a computer-readable storage medium. In some examples, computer-readable storage media may include non-transitory media. The term "non-transitory" may indicate that the storage medium is not embodied in a carrier wave or propagating signal. In some examples, non-transitory storage media may store data that may change over time (e.g., in RAM or cache). In some examples, memory 148 or 152 may be a temporary memory, meaning that the primary purpose of memory 148 or 152 is not long-term storage.

[0048] In some examples, memory 148 or 152 may be described as volatile memory, meaning that memory 148 or 152 does not retain stored contents when power to electrosurgical system 100 is turned off. Examples of volatile memory may include random access memory (RAM), dynamic random access memory (DRAM), static random access memory (SRAM), and other forms of volatile memory. In some examples, memory 148 or 152 may include one or more computer-readable storage media. In some examples, memory 148 or 152 may be configured to store a larger amount of information than volatile memory. In some examples, memory 148 or 152 may also be configured for long-term storage of information. In some examples, memory 148 or 152 may include non-volatile storage elements. Examples of such non-volatile storage elements may include magnetic hard disks, optical disks, flash memory, or forms of electrically programmable memory (EPROM) or electrically erasable and programmable memory (EEPROM).

[0049] FIGURE 3 illustrates a schematic diagram of an exemplary output device 200 of electrosurgical generator 104 of electrosurgical system 100. FIGURE 3 will be described with reference to electrosurgical system 100 shown in and described above with respect to FIGS. 1-2. In some examples, user interface 136 of electrosurgical generator 104 may include at least output device 200. Output device 200 may include a visual display 202 and an audio driver 204. Visual display 202 may be an active output display unit, such as a liquid crystal display, a plasma screen, an organic light emitting diode display, or the like. Visual display 202 may also be both an input and output display unit, such as a touch screen device that allows input in response to various outputs.

[0050] Visual display 202 may be programmed to generate or otherwise provide a variety of outputs to the user. In some examples, visual display 202 may include output displays 206A-206E and dial 208. Visual display 202, dial 208, or other output devices may provide various types of feedback in response to any factor or parameter associated with the function or operation of electrosurgical system 100 described above (FIGS. 1-2). For example, output displays 206A-206E may be any of various types of lights. In some examples, activation of at least one of displays 206A-206E may provide the user with an indication of a predetermined limit of electrosurgical instrument 108. In some examples, for example, upon connection or engagement of the electrosurgical device 106 to the electrosurgical generator 104, the light emitter 206E at the bottom of the output device 200, the light emitter 206A at the top of the output device 200, and any of the light emitters 204B-204D therebetween may be activated (e.g., lit) in an opposing manner to visually indicate to a user the remaining useful life, quantified, for example, as the total number of remaining power activations, prior to exceeding a predetermined limit of the electrosurgical instrument 108.

[0051] In some examples, such as during use of the electrosurgical device 106 during a procedure, the lights 204A-206E may be activated sequentially to provide a user with a real-time indication of the remaining useful life of the electrosurgical instrument 108. For example, light emitter 206A or 206E may be activated to indicate that the electrosurgical instrument 108 has received, without limitation, approximately 0-50 power actuations (e.g., electrical energy output) from the power source 144. In such examples, the remaining lights may be activated sequentially to indicate to a user that the electrosurgical instrument 108 has received approximately 51-100 (206B or 206D), 101-150 (206C), 151-200 (206D or 206B), or 200-250 (206E or 206A) power actuations. In some examples, the final light emitter (206E or 206A) is activated to light up in a different manner, such as by blinking or flashing, to indicate to the user that a predetermined limit of the electrosurgical instrument 108 will soon be exceeded or has been exceeded.

[0052] In some examples, all of the lights 206A-206E may be activated to indicate a maximum or starting life of the electrosurgical instrument 108 or to indicate that the useful life (e.g., a predetermined limit) of the electrosurgical instrument 108 has been exceeded. In yet another example, any of the lights 206A-206E may light up in a variety of different ways, such as by changing color or by blinking or flashing, to indicate an exact or approximate number of power actuations. For example, if light 206A is illuminated to indicate that the electrosurgical instrument 108 has undergone approximately 50-100 power actuations, a color change or blinking or flashing of light 206A may indicate to a user that the electrosurgical instrument has undergone approximately 60, 70, 80, or 90 power actuations.

[0053] In some examples, the dial 208 may include graduations or other sequential markings configured to indicate to a user the remaining useful life of the electrosurgical instrument 108. In such examples, the needle of the dial 208 may move linearly between the sequential markings to indicate, for example, that the electrosurgical instrument 108 has received approximately 51-100, 101-150, 151-200, or 200-250 power actuations, without limitation. In some examples, the movement of the needle of the dial 208 may be a function of or otherwise coupled to the actuation of the light emitters 206A-206E. In such examples, the dial 208 may be configured to function as a sub-dial and, for example, when viewed in conjunction with the light emitters 206A-206E, may indicate an exact or approximate number of power actuations.

[0054] For example, if light emitter 206A is illuminated to indicate that electrosurgical instrument 108 has undergone 50-100 power actuations, the needle position may indicate to the user that the electrosurgical instrument has undergone approximately 60, 70, 80, or 90 power actuations. User interface 136 may thereby provide the user with a visual warning corresponding to the remaining useful life of electrosurgical instrument 108 or a visual warning indicating that the useful life of electrosurgical instrument 108 (e.g., a predetermined limit) has been exceeded.

[0055] In some examples, the audio driver 204 can be activated to generate and output an audible warning or alarm. In some examples, the audio driver 204 is activated to function in a manner similar to the functions of the lights 206A-206E described above or the needle of the dial 208, such as to provide an audible indication of the remaining useful life of the electrosurgical instrument 108 before a predetermined limit of the electrosurgical instrument 108 is exceeded. For example, a steady audio signal can be emitted via the audio driver 204 that varies in pitch, volume, or tone based on the number of power actuations (e.g., electrical energy output) that the electrosurgical instrument 108 has received from the electrosurgical generator 104.

[0056] In another example, an intermittent or periodic audio signal may alternatively be emitted that varies in frequency, pitch, volume, or tone based on the number of power actuations that the electrosurgical instrument 108 has received from the electrosurgical generator 104. In yet another example, the audio signal generated and output by the audio driver 204 in response to a predetermined limit of the electrosurgical instrument 108 being exceeded by the user may be different from any other audio signal generated and output by the audio driver 204. In some examples, the audio driver 204 may be coupled to the lights 206A-206E or the dial 208 to emit an audio signal in response to any function of the lights 206A-206E or the dial 208. The user interface 136 may thereby provide the user with an audible warning corresponding to the remaining useful life of the electrosurgical instrument 108 or an audible warning indicating that the useful life of the electrosurgical instrument (e.g., a predetermined limit) has been exceeded. Although FIG. 3 is described above with reference to a predetermined limit defined by the total number of activations of the generator 144, the various elements or operations shown in and described with respect to FIG. 3 may also be used to provide an indication of other predetermined limits, such as a maximum active period of the electrosurgical instrument 108, or any of the exemplary effective time windows described with respect to FIG. 2.

[0057] 4-7 show various exemplary electrosurgical instruments 300-600 on which a hydrophobic layer can be deposited. FIGS. 4-7 are discussed with reference to various elements of the electrosurgical system 100 shown in and described above with respect thereto. The hydrophobic layer may be similar to the hydrophobic layer 140 or may be similar to further examples of hydrophobic layers or hydrophobic physical structures shown in and discussed with respect thereto, FIGS. 8-10. FIG. 4 shows an exemplary electrosurgical instrument 300 including a surgical jaw 302 on which a hydrophobic layer 304 is deposited. The electrosurgical instrument 300 may be a vessel sealing forceps and may be used, for example, to cut biological tissue 102 with a mechanical cutting device assisted with RF (radio frequency) energy derived from electrical energy generated by an electrosurgical generator 104.

[0058] The electrosurgical instrument 300 may include a hydrophobic layer 304. The surgical jaw 302 may include a first jaw 306, a second jaw 308, a first electrode plate 310, a second electrode plate 312, and a cutting element 314, a first flange 316, a second flange 318, a pivot point 320, and a channel 322. In the electrosurgical instrument 300, the first jaw 306 and the second jaw 308 may be hinged opposite one another and actuatable via one or more controls on the handpiece 114, such as the handle 118. This allows a user to open and close the surgical jaw 302 as needed during an electrosurgical procedure. The first and second electrode plates 310, 312 may be disposed in either the first jaw 306 or the second jaw 308 to enable application of electrical energy from the electrosurgical generator 104 to the biological tissue 102, for use, for example, in vessel sealing. For example, in operation, a user may close the surgical jaws 302 about the biological tissue 102 and activate the flow of electrical current to the first and second electrode plates 310, 312, such as by activating the energy button 124, to seal the biological tissue 102.

[0059] The first electrode plate 310 and the second electrode plate 312 may include bipolar or monopolar electrodes and, optionally, blades, and may be used to cut tissue. The bipolar or monopolar electrodes may use high frequency current to cut, coagulate, desiccate, or discharge coagulate tissue, etc. In a bipolar electrode configuration, current may pass through the tissue of the living tissue 102 between two closer electrodes, for example, the first electrode plate 310 and the second electrode plate 312. In a bipolar configuration, current may pass through the tissue between the tips of the two active electrodes, for example, the first electrode plate 310 and the second electrode plate 312. In a monopolar configuration, current may pass through the living tissue 102 between the electrosurgical instrument 108 and a pad on the patient's abdomen or another separate return electrode.

[0060] The first jaw 306 and the second jaw 308 may be articulated through movement of the first flange 316 and the second flange 318, respectively, about a pivot point 320. The cutting element 314 is configured to move in and out of a channel 322 and may be disposed, for example, on the body of the distal portion 130 of the shaft assembly 116. When the surgical jaws 302 are used to seal tissue, a user may extend the cutting element 314 outwardly between the surgical jaws, such as by actuating the cutting trigger 122. The cutting element 314 may thereby extend through the channel 322 and cut the biological tissue 102. A hydrophobic layer 304 may be deposited on and around at least a portion of the cutting element 314. In some cases, the hydrophobic layer 304 may be deposited in and around the channel 322 to prevent tissue build-up in the channel 322 as the cutting element 314 moves in and out of the channel 322.

[0061] 5 illustrates an exemplary electrosurgical forceps 400 having a hydrophobic layer 402 deposited thereon. The electrosurgical forceps 400 may be similar to the electrosurgical instrument 300 described above, but may be used to dissect tissue. The electrosurgical forceps 400 may include a first jaw 404, a second jaw 406, a first electrode plate 408, and a second electrode plate 410. In one example, portions of the first jaw 404 and the second jaw 406 may act as a cutting element 412, for example, instead of a stand-alone blade or knife assembly. For example, the first jaw 404 and the second jaw 406 may be serrated to enable these actions.

[0062] In one example, the electrosurgical forceps 400 may include a cutting element, such as cutting element 314 shown in FIG. 4, located between the first jaw 404 and the second jaw 406. The first jaw 404 and the second jaw 406 may also be curved to allow for articulation to ensure grasping, dissection, retraction, and coagulation of the biological tissue 102. The first electrode plate 408 and the second electrode plate 410 may be fully or partially coated with a hydrophobic layer 402.

[0063] 6 shows an example of a distal portion 502 of an electrosurgical pencil 500 having a hydrophobic layer 504 deposited thereon. The electrosurgical pencil 500 may include a cutting element 506. In such an example, the electrosurgical pencil 500 itself may function as the cutting element 506 in various electrosurgical procedures and may be at least partially coated with a hydrophobic layer 504. The electrosurgical pencil 500 may be used for precise surgical techniques as needed. Alternatively, the hydrophobic layer 504 may be deposited on the cutting portion of an electrosurgical spatula.

[0064] 7 shows a distal portion 602 of a laparoscopic loop 600 having a hydrophobic layer 604 disposed thereon. The laparoscopic loop 600 may include a cutting element 606 and loop sections 610 and 612, which may meet together at the cutting element 606. The cutting element 606 may be at least partially covered by the hydrophobic layer 604. The laparoscopic loop 600 may be coupled to an electrosurgical generator 104 to deliver bipolar energy to the living tissue 102, for use in, for example, a cervical hysterectomy procedure.

[0065] 8-9 show schematic diagrams of examples of hydrophobic layers 700 deposited on a surface 702 of an electrosurgical device. FIGS. 8-9 are discussed simultaneously below. For example, the hydrophobic layer 700 may form a hydrophobic physical structure 704 on the surface 702. The hydrophobic layer 700 may be similar to any hydrophobic layer, and the surface 702 may be any surface of any component of the various electrosurgical devices or instruments shown in and discussed above with respect to FIGS. 1-7. In general, the thickness or depth of the hydrophobic layer 700 may range from about 10 nm to about 300 nm to provide non-stick functionality and related benefits. As described in the examples below, various portions of this range may provide specific or additional benefits, as well as tissue adhesion resistance and sensing capabilities.

[0066] In some examples, the hydrophobic layer 700 can be a thin coating and have a thickness in the range of, but not limited to, about 10 to 30 nanometers. In some examples, the hydrophobic layer 700 can have a thickness in the range of about 10 to 20 nanometers. In another example, the hydrophobic layer 700 can have a thickness of less than 20 nanometers, such as about 15 nanometers. In some examples, the thickness of the hydrophobic layer 700 can define or otherwise indicate a predetermined limit of the electrosurgical instrument 108 or electrosurgical device 106. For example, increasing the thickness of the hydrophobic layer can increase the maximum number of actuations of the power source 144 (FIG. 2) that the hydrophobic layer 700 can receive before it no longer effectively functions to reduce surface adhesion of the surface to which it is applied or deposited, or can increase the maximum active period of the hydrophobic layer 700. In some examples, including but not limited to, a hydrophobic layer 700 having a thickness of about 5-10 nanometers, 11-15 nanometers, 16-20 nanometers, 21-25 nanometers, or 26-30 nanometers will no longer effectively reduce surface adhesion after about, including but not limited to, 100-200, 201-300, 301-400, or 401-500 power actuations, respectively.

[0067] In some examples, but not limited to, a hydrophobic layer 700 having a thickness of about 5-10, 11-15, 16-20, 21-25, or 26-30 nanometers may implement a maximum active period of about, but not limited to, 30-60 minutes, 61-120 minutes, 121-180 minutes, 181-240 minutes, or 240-300 minutes. Any number of actuations or any active period may be used depending on the characteristics of the device to define the predetermined limit. Depending on the characteristics of the device, several ranges or thresholds may be desirable. Additionally, a combination of actuation ranges / thresholds and active periods may be used to define the predetermined limit. In the example limits described herein above, the hydrophobic layer 700 or other coating may change from a first state to a second state (e.g., decompose, degrade, erode). For example, in a first state, hydrophobic layer 700 may have a thickness sufficient to reduce surface adhesion between at least a portion of electrosurgical instrument 108 (FIGS. 1-4) or electrosurgical device 106 (FIGS. 1-4) and biological tissue 102 (FIG. 1). In a second state, hydrophobic layer 700, or a portion thereof, may erode to a thickness insufficient to reduce surface adhesion between at least a portion of electrosurgical instrument 108 or electrosurgical device 106 and biological tissue 102. For example, the second state may be defined as a predetermined percentage of a starting thickness of hydrophobic layer 700 or other coating, such as, but not limited to, about 25-40, 41-55, 56-70, 71-85, or 86-100 percent of the starting thickness.

[0068] In another example, the material used for the hydrophobic layer 700 may affect the maximum number of power supply actuations that the hydrophobic layer 700 can receive. The hydrophobic layer 700 may be configured to allow the passage of electrical energy so that the electrosurgical instrument may transmit or apply electrical energy to biological tissue. For example, the hydrophobic layer 700 may be a photocapacitive or photoresistive element configured to allow electrical energy to pass through the hydrophobic layer 700. In such an example, the hydrophobic layer 700 may be applied directly to a surface 702, such as a cutting element of an electrosurgical device and an electrode, such as any electrode plate, of an electrosurgical instrument coupled to or otherwise included in the electrosurgical device. In some cases, an adhesive may be used to apply the hydrophobic layer 700 to a surface 702 of the electrosurgical device.

[0069] In some examples, the hydrophobic layer 700 may include a polymer-based coating, such as a fluoropolymer type coating. In some examples, the hydrophobic layer 700 may include a polytetrafluoroethylene (PTFE) coating. In some examples, the hydrophobic layer 700 may include a polysiloxane or fluorosilane coating. In such examples, materials such as silicones and silicone resins may be used. In some examples, the silicones and silicone resins are applied using a plasma deposition process to precisely control the thickness and to withstand the heat generated, for example, during sealing of tissue or blood vessels. Silicone resins suitable for the hydrophobic layer 700 may include, but are not limited to, polydimethylsiloxane, polyester modified methylphenyl polysiloxanes such as polymethylsilane and polymethylsiloxane, and hydroxyl functional silicone resins.

[0070] In some examples, the hydrophobic layer 700 can be made from a composition including siloxane, which can include hexamethyldisiloxane, hexadimethylsiloxane, tetramethylsilane, hexamethyldisilazane, or any combination thereof. In some examples, the hydrophobic layer 700 can be a polydimethylsiloxane ("PMDSO") coating. In some examples, the hydrophobic layer 700 can be a hexamethyldisiloxane ("HMDSO") coating. In some examples, the hydrophobic layer 700 can be tetramethyldisiloxane (TMDSO or TMDS). In yet another example, the hydrophobic layer 700 can include a thin layer of hexamethyldisiloxane (HMDSO), such as having a thickness of about 1-5 nanometers. Generally, HMDSO is electrically resistive, but the thinness of such a layer can allow the passage of electrical energy.

[0071] In some examples, the hydrophobic layer 700 may include an etched coating, such as one or more hydrophobic pillars superimposed on the electrode plate of an electrosurgical instrument. In such examples, the nanostructure of the hydrophobic pillars may function as a superhydrophobic coating with low surface energy to reduce tissue adhesion or stiction. Such etched coatings may be formed in any suitable pattern for the hydrophobic layer 700 to reduce or prevent tissue adhesion, and may be applied, for example, by printing, chemical etching, laser etching, chemical bombardment, or other techniques. Although various exemplary materials for the hydrophobic layer 700 are discussed above, any material that can provide the desired functionality (e.g., reducing adhesion of the surface 702 while simultaneously maintaining effective electrical transmission through, for example, allowing for sealing of tissue or blood vessels) may be used as the hydrophobic layer 700, provided the material has suitable biocompatibility. In one example, such materials may be porous, allowing or otherwise improving electrical transmission through the material.

[0072] The hydrophobic layer 700 may define a hydrophobic physical structure 704 deposited on all or only a portion of any surface of the electrosurgical device or instrument. The hydrophobic layer 700 may define different hydrophobic physical structures, such as for use on specific or different surfaces or components of the electrosurgical device or instrument. For example, the hydrophobic layer 700 may define the hydrophobic physical structure 704 on only certain portions or areas of the electrosurgical instrument or may define different hydrophobic physical structures on other portions. In one example, the hydrophobic physical structure 704 may be deposited on any insulating elements on or around the cutting element of the electrosurgical instrument, but not on the cutting edge or other cutting means of the cutting element.

[0073] The hydrophobic physical structure 704 may include irregularities 706. The irregularities 706 may define a height 708 and a pitch 710. In some examples, the hydrophobic physical structure 704 may be described or defined by the following equation:

[0074]

number

[0075] In such an example, Λ is the contact line density, Λ is the critical contact line density, ρ = density of the droplet, g = acceleration due to gravity, V = volume of the droplet, θ = apparent advancing contact angle, θ = advancing contact angle of a smooth substrate, γ = surface tension of the liquid, and w = tower wall angle. The contact line density Λ is defined as the total perimeter of the asperities over a given unit area. In one example, if Λ > Λ, the droplet 712 of the liquid may be suspended in a Cassie-Baxter state. Otherwise, the droplet 712 collapses into a Wenzel state. In one example, the droplet 712 is in a Cassie-Baxter state and a superhydrophobic state exists, for example forming or defining a low adhesion surface.

[0076] With respect to FIG. 8, the droplet 712 rests in a Cassie-Baxter state on the asperities 706 at the interface 714. The asperities 706 are shown in a rectangular shape for illustrative purposes, but the invention is not so limited. For example, the shape formed by each of the asperities 706 is taken into account in the above equation, at least via the tower wall angle (e.g., "w"). With respect to FIG. 9, the asperities 706 are formed directly from the bulk material and not from a separate coating. In one example, the method of forming the asperities 706 directly from the bulk material includes chemical etching. In one example, the method of forming the asperities 706 directly from the bulk material includes laser etching or ablation. In another example, the method of forming the asperities 706 directly from the bulk material includes ion etching.

[0077] Further, as shown in FIG. 9, the hydrophobic physical structure 704 can be part of the coating 703 that forms or otherwise defines a direct interface 705 with the surface 702. The asperities 706 can be formed by applying nanoparticles to the surface 702 to form the coating 703. In some examples, the asperities 706 can be formed by applying nanoparticles to the surface of the coating 703. In some examples, the nanoparticles can include hexamethyldisiloxane (HMDSO) particles. In some examples, the nanoparticles can include tetramethyldisiloxane (TMDSO) particles. In yet another example, the nanoparticles can include fluorosilane particles. While the above examples describe various nanoparticle materials, other nanoparticle materials are within the scope of the present invention. In additional examples, the hydrophobic chemistry of the nanoparticles can provide superior hydrophobicity in combination with the nanoscale asperity structure as shown in FIG. 9 compared to the hydrophobic chemistry alone.

[0078] Figure 10 shows an example of a laser etched surface 800 having a hydrophobic physical structure 802 formed thereon. The hydrophobic physical structure 802 may be similar to the hydrophobic layer 700, including, for example, the hydrophobic physical structure 704 shown in and discussed above with respect to Figures 8-9. The laser etched surface 800 may be any surface of any component of the various electrosurgical devices or instruments shown in and discussed above with respect to Figures 1-9.

[0079] The application of the hydrophobic physical structure 802 may be accomplished using any system and process that allows for precise control of the thickness of the coating. In some examples, HMDSO is deposited onto a conductive sealing plate, such as the electrode plate of various electrosurgical instruments, using plasma-enhanced chemical vapor deposition (PECVD) or other suitable methods, such as atmospheric pressure plasma-enhanced chemical vapor deposition (AP-PECVD). In such examples, the application of the polydimethylsiloxane coating may be accomplished using a system and process that includes a plasma device coupled to a power source, a source of liquid and / or gaseous ionizable media (such as oxygen), a pump, and a vacuum chamber.

[0080] The power source may include any suitable components for powering or impedance matching the plasma device. For example, the power source may be a radio frequency generator or other power source capable of generating electrical power to ignite and sustain an ionizable medium to generate a plasma effluent. As shown in FIG. 10, a Gaussian hole array may be formed by applying laser energy to a laser etched surface 800 of an electrosurgical instrument in a controlled, regular pattern to form, for example, a plurality of holes 804. The shape of each of the holes 804 may be characterized as Gaussian due to the energy distribution of the laser energy used in forming the array. In such a process, a plurality of asperities 806 may also be formed, spaced apart in an array that provides a Cassie-Baxter condition, for example, as described above with respect to FIGS. 8-9. Exemplary droplets 808 are also shown on the hydrophobic physical structure 802. The droplets 808 may be similar to any of the droplets 712 shown in and described above with respect to FIGS. 8-9.

[0081] 11 illustrates a flow diagram of an exemplary method 900 for preventing an electrosurgical generator from outputting electrical energy to an electrosurgical instrument after a limit of the electrosurgical instrument has been exceeded. The steps or operations of method 900 are illustrated in a particular order for convenience and clarity. The operations described may be performed in parallel or in another order without significantly affecting other operations. The described method 900 includes operations that may be performed by multiple different actors, devices, and / or systems. It is understood that a subset of the operations described in method 900 may be attributable to a single actor device or system and may be considered a separate, stand-alone process or method.

[0082] Method 900 may begin at operation 902. Operation 902 may include receiving by the electrosurgical generator limitations of the electrosurgical instrument. For example, a user may establish an electrical connection between the electrosurgical generator and the electrosurgical instrument using an electrical connector and / or a network or wireless communication. Establishing such a connection, the electrosurgical generator may transfer data to or receive data from the electrosurgical instrument and, in response, the electrosurgical generator may indicate or otherwise provide the limitations of the electrosurgical instrument (e.g., useful life) to the user. Operation 902 may optionally include receiving by the electrosurgical generator limitations of the electrosurgical instrument including exchanging information between the electrosurgical instrument and the electrosurgical generator via an electrical connector that establishes electrical communication between the electrosurgical instrument and the electrosurgical generator, including, for example, looking up the limitations of the electrosurgical instrument in a memory or database of the electrosurgical generator. For example, by connecting an electrosurgical instrument to the electrosurgical generator, the electrosurgical generator can automatically match data stored in the memory of the electrosurgical instrument with individual database entries (e.g., data sets) on the electrosurgical generator's database or on a database in network communication with the electrosurgical generator to obtain predetermined limits for the electrosurgical instrument.

[0083] Thus, the electrosurgical generator may read information from the electrosurgical instrument and know, for example, the maximum number of power activations the electrosurgical instrument can undergo, or the maximum active period. Such exchange of information may include generating an audible or visual warning indicative of the limitations of the electrosurgical instrument. For example, the electrosurgical generator may include a user interface, which may include output devices such as, for example, a visual display, one or more dials, and an audio driver. In some examples, activation of at least one of the visual display, the one or more dials, and the audio driver may provide an indication of the limitations of the electrosurgical instrument to the user. In some examples, the indication may be or even include an indication of the remaining life of the electrosurgical instrument, for example, a quantified amount of remaining usage before the limitations of the electrosurgical instrument are exceeded.

[0084] Operation 902 may optionally include that the limits further include a valid time window, where connecting the electrosurgical instrument to the electrosurgical generator includes starting a timer to prevent operation of the power source after the valid time window has been exceeded. For example, the valid time window may be the number of hours or minutes in which the electrosurgical procedure is completed, measured, for example, by a clock or timer in the electrosurgical generator, beginning after a first engagement or connection of the electrosurgical instrument to the electrosurgical generator or beginning after a first disengagement or disconnection of the electrosurgical instrument from the electrosurgical generator.

[0085] Operation 902 may optionally include receiving, by the electrosurgical generator, the limitations of the electrosurgical instrument including exchanging information between an RFID or NFC transceiver of the electrosurgical generator and an RFID or NFC tag of the electrosurgical instrument. For example, the electrosurgical generator may include a radio frequency identification (RFID) or near field communication (NFC) wireless transceiver and the electrosurgical instrument may include an inlay or hard tag, including, for example, an antenna and memory. In such an example, connecting the electrosurgical instrument to the electrosurgical generator may include powering the RFID or NFC tag, for example, to enable wireless data transmission and reception between the RFID or NFC transceiver and the RFID or NFC tag.

[0086] Method 900 may include operation 904. Operation 904 may include activating a power source of the electrosurgical generator to output electrical energy to the electrosurgical instrument and storing a total number of power source actuations in a memory of the electrosurgical generator, where the limit of the electrosurgical instrument is a maximum number of power source actuations that can be received by the electrosurgical instrument before a coating deposited on at least a portion of the electrosurgical instrument changes from a first state to a second state, where the coating comprises a material that has a surface adhesion to tissue that is less than the surface adhesion to tissue of a material of the portion of the electrosurgical instrument.

[0087] For example, a user may engage biological tissue with one or more surfaces of an electrosurgical instrument and then actuate an energy button, such as one located on an electrosurgical device that contains or otherwise includes the electrosurgical instrument, to activate a power source in the electrosurgical generator and cause the electrosurgical instrument to output electrical energy via the electrosurgical device. In some examples, a single actuation of the energy button may repeatedly activate the power source to output cyclical, intermittent, or otherwise variable electrical energy while causing the electrosurgical generator to count, tally, and store the total number of power source actuations. In some examples, counting, tallying, and storing the total number of power source actuations may include counting, tallying, and storing the length (e.g., time span) of each actuation in a memory of the electrosurgical generator or electrosurgical instrument.

[0088] Operation 904 may optionally include activating a power source of the electrosurgical generator including generating an audible or visual warning corresponding to the remaining number of power source activations before a limit of the electrosurgical instrument is exceeded. For example, the electrosurgical generator may include a user interface, which may include output devices such as, for example, a visual display, one or more dials, and an audio driver. In some examples, activation of at least one of the visual display, one or more dials, and an audio driver may provide the user with a real-time indication of the remaining life of the electrosurgical instrument, for example, a quantified amount of remaining usage before a limit of the electrosurgical instrument is exceeded. In some examples, activation of at least one of the visual display, one or more dials, and an audio driver may provide the user with an indication that the electrosurgical instrument has no remaining life, for example, when a limit of the electrosurgical device has been exceeded.

[0089] Operation 904 may optionally include that the limit further includes a maximum active period and that operating the electrosurgical instrument to repeatedly activate the power source includes starting a timer upon each activation of the power source, stopping the timer upon each non-activation of the power source, and storing the total active period in a memory of the electrosurgical generator. For example, a user may operate an energy button located on an electrosurgical device that contains or otherwise includes an electrosurgical instrument to activate a power source of the electrosurgical generator and cause the electrosurgical instrument to output electrical energy via the electrosurgical device. In such an example, a single activation of the energy button may repeatedly activate the power source to output cyclic, intermittent, or otherwise variable electrical energy while causing the electrosurgical generator to count, tally, and store the length (e.g., time span) of each power source activation in a memory of the electrosurgical generator.

[0090] Method 900 may include operation 906. Operation 906 may include activating the power source and preventing the power source from operating by storing in a memory of the electrosurgical generator a maximum number of power source actuations that define the limitations of the electrosurgical instrument. For example, a user may operate an energy button, such as that located on an electrosurgical device that contains or otherwise includes the electrosurgical instrument, to activate the electrosurgical generator a total number of times less than, equal to, or greater than the maximum number of power source actuations that define the limitations of the electrosurgical instrument. In such an example, the electrosurgical generator may then disable the power source, for example, by preventing or otherwise preventing the electrosurgical instrument from effectively invoking actuation via operation of the energy button, or by preventing or otherwise preventing electrical energy generated upon activation of the power source from being output to the electrosurgical instrument by interrupting signal communication between the electrosurgical device and the power source.

[0091] Operation 906 optionally or alternatively includes preventing output of electrical energy from the electrosurgical generator to the electrosurgical instrument, preventing activation of the power source by operating the electrosurgical instrument and storing in the memory of the electrosurgical generator a maximum active period that defines the limits of the electrosurgical instrument. For example, a user may operate an energy button, such as that located on an electrosurgical device that contains or otherwise includes the electrosurgical instrument, to cause the electrosurgical generator to store in the memory of the electrosurgical generator a total active period that is less than, equal to, or greater than the maximum active period that defines the limits of the electrosurgical instrument. The electrosurgical generator may then disable the power source as described above.

[0092] Method 900 may optionally include operation 908. Operation 908 may include storing, by the electrosurgical generator, information in a memory of the electrosurgical instrument indicating that a limit of the electrosurgical instrument has been exceeded. For example, a user may actuate an energy button, such as that located on an electrosurgical device that contains or otherwise includes the electrosurgical instrument, causing the electrosurgical generator to store in the memory of the electrosurgical generator a total active period equal to or greater than the maximum active period or maximum number of power supply activations that define the limit of the electrosurgical instrument.

[0093] Method 900 may optionally include operation 910. Operation 910 may include activating the power source after a limit of the electrosurgical instrument is exceeded, where the limit is exceeded during a single engagement of the electrosurgical instrument with the electrosurgical generator. For example, the electrosurgical generator may be configured to allow one or more user inputs, such as operation of an energy button after a limit of the electrosurgical instrument is exceeded, to cause the electrosurgical generator to output electrical energy to the electrosurgical instrument if various conditions are met, such as, for example, providing that the electrosurgical instrument is not disconnected from the electrosurgical generator between operations 902 and 908, or, in additional examples, providing that a valid time window, such as the beginning after connecting or disconnecting the electrosurgical instrument to or from the electrosurgical generator, or a maximum active period of the electrosurgical instrument is not exceeded.

[0094] Operation 910 may optionally include disconnecting the electrosurgical instrument from the electrosurgical generator, where disconnecting the electrosurgical instrument includes preventing the electrosurgical generator from outputting electrical energy to the electrosurgical instrument after reconnecting the electrosurgical instrument to the electrosurgical generator. For example, a user may electrically disconnect or isolate the electrosurgical generator from the electrosurgical instrument using an electrical connector. In such an example, the electrosurgical generator may be configured to transmit data to or receive data from a memory of the electrosurgical instrument, for example, in response to the user exceeding a maximum number of power supply activations or a maximum active period of the electrosurgical instrument that defines the limitations of the electrosurgical instrument. The data may be configured to enable the electrosurgical generator or another electrosurgical generator to recognize that the electrosurgical instrument has expired, for example if the electrosurgical instrument is later reconnected to another electrosurgical generator in preparation for a subsequent electrosurgical procedure. In response, the electrosurgical generator may disable the power source as described above.

[0095] FIG. 12A shows a perspective view of an electrosurgical instrument 1000 having a hydrophobic layer 1002 deposited thereon. FIG. 12B shows a cross-sectional view of an electrosurgical instrument 1000 having a hydrophobic layer 1002 deposited thereon. FIGS. 12A-B are discussed below with reference to the electrosurgical system 100 shown in and described above with respect thereto. The electrosurgical instrument 1000 may include any of the various aspects or features of the electrosurgical devices discussed in U.S. Patent Application Publication No. 2021 / 0307859, the entire contents of which are incorporated herein by reference. The electrosurgical instrument 1000 may be similar to the electrosurgical instrument 108 described above, at least in that the electrosurgical instrument 1000 may include a hydrophobic layer 1002, a first jaw 1004, a second jaw 1006, a first electrode plate 1008, and a second electrode plate 1010. The first electrode plate 1008 and the second electrode plate 1010 may be integral with the first jaw 1004 and the second jaw 1006, or the first electrode plate 1008 and the second electrode plate 1010 may be coupled to the first jaw 1004 and the second jaw 1006, respectively.

[0096] The first jaw 1004 or the second jaw 1006 of the electrosurgical instrument 1000 may include one or more jaw stops 1012. The jaw stop 1012 may generally be a protrusion or projection that extends outwardly from the first jaw 1004 or the second jaw 1006, e.g., beyond the first electrode plate 1008 or the second electrode plate 1010, toward the second jaw 1006 or the first jaw 1004, respectively. The jaw stop 1012 may be similar to the stops described in detail in U.S. Patent Application Publication No. 2021 / 0307859, e.g., in that the jaw stop 1012 may be configured to prevent conductive electrical contact or shorting between the first electrode plate 1008 and the second electrode plate 1010. For example, the jaw stops 1012 can prevent the first electrode plate 1008 from contacting the second electrode plate 1010 when the electrosurgical instrument 1000 is pivoted from an open position to a closed position as shown in and described with respect to FIGS. 12A-12B. Each of the jaw stops 1012 can define an outer surface 1014 (FIG. 12B). The outer surface 1014 can be the outermost, or otherwise distal-most, surface of each of the jaw stops 1012, for example, relative to the first jaw 1004 or second jaw 1006. For example, the outer surface 1014 of each of the jaw stops 1012 disposed on the first jaw 1004 can contact the second electrode plate 1010 of the second jaw 1006, or the outer surface 1014 of each of the jaw stops 1012 disposed on the second jaw 1006 can contact the first electrode plate 1008, when the electrosurgical instrument 1000 is pivoted from the open position to the closed position.

[0097] The jaw stops 1012 may be electrically insulating. For example, each of the jaw stops 1012 may be made from a non-conductive material, including, but not limited to, ceramic, plastic, glass, rubber, or porcelain. Any of the jaw stops 1012 may further be fully or partially covered by the hydrophobic layer 1002. Alternatively, the jaw stops 1012 may be formed entirely from the material from which the hydrophobic layer 1002 is made, such as polydimethylsiloxane, hexadimethyldisiloxane, and tetramethyldisiloxane. In view of the above, the jaw stops 1012 may prevent conductive electrical contact or shorting between the first electrode plate 1008 and the second electrode plate 1010 by preventing the transfer of electrical energy therebetween when the electrosurgical instrument 1000 is in the closed position. The hydrophobic layer 1002 may be similar to any of the hydrophobic layers or other coatings shown in and described with respect to FIGS. 1-11 above. The hydrophobic layer 1002 provides electrical resistance to the direct passage of electrical energy between various conductive components of the electrosurgical instrument 1000, such as the first electrode plate 1008 and the second electrode plate 1010, or through the biological tissue 102 (FIG. 1) when the biological tissue 102 is positioned therebetween. For example, the hydrophobic layer 1002 may define a predetermined starting resistance value or a known resistance value (e.g., prior to electrosurgical use of the electrosurgical instrument 1000), such as, but not limited to, an impedance of about 0-1 ohms, 1-3 ohms, or 4-5 ohms.

[0098] 1-11, the hydrophobic layer 1002 may erode or decrease in thickness as a function of normal electrosurgical use, for example, being partially reduced in thickness each time the power source 144 of the electrosurgical generator 104 is activated to output electrical energy to the electrosurgical instrument 1000, or continuously during active periods when the power source 144 is outputting electrical energy to the electrosurgical instrument 1000. Thus, the amount of impedance or resistance that the hydrophobic layer 1002 contributes to the passage of electrical energy therethrough may decrease as the hydrophobic layer 1002 erodes. Thus, a resistance value associated with the hydrophobic layer 1002 during an electrosurgical procedure may be indicative of the thickness of the hydrophobic layer 1002 at the time such resistance value is measured or otherwise obtained. In addition to the various methods and techniques described with respect to Figures 1-11, electrosurgical generator 104 can be configured to prevent the output of electrical energy to electrosurgical device 106 when predetermined limits of electrosurgical instrument 108 (such as electrosurgical instrument 1000) are met or exceeded by monitoring resistance values ​​associated with (e.g., defined by) hydrophobic layer 1002 at various times during the electrosurgical procedure.

[0099] For example, the control circuit 134 (FIGS. 1-2) of the electrosurgical generator 104 may be configured to measure at least one resistance value associated with the hydrophobic layer 1002 deposited on the first electrode plate 1008 and the second electrode plate 1010 via the measurement circuit 146 (FIG. 2) when the power source 144 (FIG. 2) is outputting electrical energy to the electrosurgical instrument 1000, for example, according to any of the methods and techniques described in WO 2020 / 227519. For example, the at least one resistance value may be a direct current (DC) or alternating current (AC) electrical value (such as a resistance or impedance) of the hydrophobic layer 1002, a voltage difference transmitted across the hydrophobic layer 140 and / or a current conducted by the hydrophobic layer 140, or a phase angle between a voltage difference transmitted across the hydrophobic layer 140 and a current conducted by the hydrophobic layer 140. Thus, the control circuit 134 of the electrosurgical generator 104 may be configured to measure at least one resistance value associated with the hydrophobic layer 1002 deposited on the first and second electrode plates 1008, 1010 when the first and second electrode plates 1008, 1010 are in contact with one another or with the biological tissue 102 when the electrosurgical instrument 1000 is in a closed position, as discussed in more detail with reference to FIG 14. In another example, the control circuit 134 of the electrosurgical generator 104 may be configured to measure at least one resistance value associated with the hydrophobic layer 1002 deposited on the first and second electrode plates 1004, 1006 when the first and second electrode plates 1008, 1010 are not in contact with one another when the electrosurgical instrument 1000 is in an open position. For example, the first electrode plate 1008 and the second electrode plate 1010 may be positioned in contact with a conductive member or liquid medium, such as, but not limited to, saline, extending between the jaws to enable the transfer of electrical energy between the first electrode plate 1008 and the second electrode plate 1010.

[0100] The control circuit 134 may be configured to determine whether to permit or prevent operation of the generator 144 based on at least one measured resistance value, for example, whether the at least one measured resistance value is less than or equal to a predetermined threshold resistance value (e.g., a resistance value indicative of or otherwise corresponding to a minimum thickness of the hydrophobic layer 1002 before the hydrophobic layer 1002 changes from a first state to a second state as described with respect to FIGS. 8-9 above) or a change (e.g., delta) greater than or equal to the difference between the starting resistance value and the threshold resistance value. In other words, the measured resistance value may be compared to a starting resistance value when the hydrophobic layer 1002 is new or unworn, and operation of the generator 144 may be prevented if the measured resistance value is a certain percentage of the starting resistance value. The electrosurgical system 100 may thereby monitor the thickness of the hydrophobic layer 1002 and prevent the output of electrical energy to the electrosurgical instrument 1000 when a predetermined limit (e.g., a minimum thickness) of the electrosurgical instrument 1000 is reached or exceeded.

[0101] In some examples, one or more of the jaw stops 1012 of the electrosurgical instrument 1000 may be configured to aid in monitoring the thickness of the hydrophobic layer 1002 during an electrosurgical procedure. For example, the jaw stop 1012 may be configured to cause a conductive electrical contact or short within the electrosurgical instrument 1000 when a predetermined limit of the electrosurgical instrument 1000 is reached or exceeded, such as when the hydrophobic layer 1002 erodes to a minimum thickness or otherwise changes from a first state to a second state in either the first electrode plate 1008, the second electrode plate 1010, or the jaw stop 1012. In such examples, the jaw stop 1012 may include a conductive element 1016 (FIG. 12B). The conductive element 1016 may generally be one or more conductive filaments or wires, such as, but not limited to, silver, copper, gold, or other metal strands. The conductive element 1016 may extend longitudinally through either of the jaw stops 1012, such as between the first electrode plate 1008, the second electrode plate 1010, or other electrical components of the electrosurgical instrument 1000 and the respective outer surface 1014 of the jaw stop 1012. In some examples, the conductive element 1016 of the jaw stop 1012 may be in electrical communication with the electrosurgical generator 104, such as via a circuit extending through the first jaw 1008 and the second jaw 1006 to the electrosurgical generator 104, but may be electrically isolated from a circuit extending between the first and second electrode plates 1008, 1010 and the electrosurgical generator 104, such as to prevent the jaw stop 1012 from interfering with a vessel sealing or tissue cauterizing action achieved by the application of electrical energy to biological tissue via the first and second electrode plates 1008, 1010.

[0102] Any of the jaw stops 1012 may thereby be in electrical communication with various electrical components of the electrosurgical instrument 1000, electrosurgical device 106, or electrosurgical generator 104, including, for example, the control circuit 134 and the measurement circuit 146. In such an example, the conductive elements 1016 and the outer surface 1014 may be covered by the hydrophobic layer 1002 at the start of the electrosurgical procedure, for example, when the hydrophobic layer 1002 defines a starting thickness. Subsequently, when the hydrophobic layer 1002 is eroded to a minimum thickness or otherwise changed from a first state to a second state (e.g., completely or entirely eroded) on the outer surface 1014 of at least one of the jaw stops 1012, at least a portion of the conductive element 1016 along the outer surface 1014 may be exposed, such that the conductive element 1016 may, in various examples, come into contact with the conductive element 1016 of the first electrode plate 1008, the second electrode plate 1010, or at least one jaw stop 1012 positioned opposite the first jaw 1004 or the second jaw 1006, allowing electrical energy to transfer therebetween.

[0103] In another example, the jaw stop 1012 may be further configured to create a conductive electrical contact or short when the first and second electrode plates are in contact with the biological tissue 102. For example, the conductive element 1016 may include at least two conductive filaments or wires, such as, but not limited to, silver, copper, gold, or other metal strands, spaced laterally within the jaw stop 1012. Subsequently, when the hydrophobic layer 1002 erodes to a minimum thickness or otherwise changes from a first state to a second state (e.g., erodes completely or entirely) on the outer surface 1014 of at least one of the jaw stops 1012, at least a portion of the at least two conductive filaments or wires of the conductive element 1016 may be exposed to allow electrical energy to travel therebetween. In a further example, the thickness of the hydrophobic layer 1002 deposited on one or more jaw stops 1012 on the first jaw 1004 and one or more jaw stops 1012 on the second jaw 1006 may be thinner or otherwise reduced in thickness than the thickness of the hydrophobic layer 1002 deposited on the first electrode plate 1008 or the second electrode plate 1010. This may, for example, cause a conductive electrical contact or short between the jaw stop 1012 on the first jaw 1004 and the jaw stop 1012 on the second jaw 1006, after which the hydrophobic layer 1002 deposited on the first electrode plate 1008 and the second electrode plate 1010 may erode to a minimum thickness before the hydrophobic layer 1002 changes from a first state to a second state. In view of the above, the jaw stops 1012 may create a conductive electrical contact, or short, within at least one of the jaw stops 1012 by the conductive element 1016. Jaw stop 1012 may be configured to thereby create a conductive electrical contact or short within electrosurgical instrument 1000. In response, control circuitry 134 may detect the conductive electrical contact or short, store an indication of the conductive electrical contact or short in, for example, memory 152 (FIG. 2) or memory 148 (FIG. 2), and inhibit operation of generator 144.In some examples, as will be further discussed, the control circuit 134 of the electrosurgical generator 104 is configured to monitor the delta between the starting resistance value on the jaw stop 1012 and at least one measured resistance value to help determine when conductive electrical contact or a short occurs and may generate an audible or visual warning, for example, before a conductive electrical contact or short occurs.

[0104] FIG. 13 illustrates an exemplary waveform 1100 indicative of electrical energy traveling through biological tissue. FIG. 13 is described with reference to the electrosurgical system 100 shown in and described with reference to FIGS. 1-12. As described with respect to FIGS. 12A-12B, the electrosurgical generator 104 (FIGS. 1-2) may be configured to apply electrical energy to the biological tissue 102 and measure a resistance associated with the biological tissue 102 (FIG. 1) in conductive communication with at least one electrode, electrode plate, or other conductive feature of the electrosurgical instrument 108 (FIGS. 1-2), such as according to the methods and techniques described in WO 2020 / 227519. The electrosurgical generator 104 may be configured to perform similar methods and techniques to measure a resistance associated with the hydrophobic layer 140 (FIG. 1) and, for example, to determine whether to enable or prevent operation of the power source 144 (FIG. 2) based on at least one measured resistance associated with the hydrophobic layer 140. For example, control circuitry 134 (FIGS. 1-2) of electrosurgical generator 104 may be configured to control power source 144 to cause power source 144 to apply electrical energy to electrosurgical instrument 108 (FIGS. 1-2) and to any biological tissue in conductive communication therewith in the first phase 1102 and / or the second phase 1104.

[0105] During the first phase 1102, the control circuit 134 may operate the power source 144 to output a sufficient amount of electrical energy to enable the control circuit 134 to obtain at least one measured resistance value associated with the hydrophobic layer 140, at one or more time points, for example, at the hydrophobic layer 1002 deposited on the first electrode plate 1008, the second electrode plate 1010, or the jaw stop 1012 of the electrosurgical instrument 1000 of FIGS. 12A-12B. In various examples, the measured resistance value may be, without limitation, either a direct current (DC) or alternating current (AC) electrical value (such as resistance or impedance) of the hydrophobic layer 1002, a voltage difference delivered across the hydrophobic layer 140 and / or a current conducted by the hydrophobic layer 140, or a phase angle between the voltage difference delivered across the hydrophobic layer 140 and the current conducted by the hydrophobic layer 140. For example, during the first phase 1102, the amount of electrical energy output by the generator 144 may be low, but not zero, such that the amount of energy output by the generator 144 does not substantially affect or significantly alter biological tissue in conductive communication with the electrosurgical instrument 108. For example, the amount of energy output by the generator 144 during the first phase 1102 may be, without limitation, approximately 4-6 watts, 7-9 watts, or 10-12 watts. The first phase 1102 may also be limited to a predetermined or user-selected time limit or time window. For example, the time window of the first phase 1102 may be, without limitation, approximately 200-250 milliseconds, 251-300 milliseconds, or 301-350 milliseconds long.

[0106] Accordingly, based on at least one measured resistance value associated with hydrophobic layer 140, control circuitry 134 may be configured to determine whether to enable or prevent subsequent actuation of power source 144. For example, control circuitry 134 may compare a measured resistance value associated with hydrophobic layer 140 to other resistance values, such as a starting resistance value, a previously measured resistance value, or a threshold resistance value, associated with hydrophobic layer 140 that correspond to or are otherwise indicative of the thickness of hydrophobic layer 140, to help determine if or when hydrophobic layer 140 changes from a first state to a second state. Electrosurgical system 100 may thereby monitor the thickness of hydrophobic layer 140 and prevent the output of electrical energy to electrosurgical instrument 108 when the thickness of hydrophobic layer 140 reaches or exceeds a predetermined limit (e.g., a minimum thickness) of electrosurgical instrument 108.

[0107] If the control circuit 134 determines that the limits of the electrosurgical instrument 108 have not been reached or exceeded and that the electrosurgical instrument 108 is conductively engaged with biological tissue, the control circuit 134 may be configured to proceed to a second stage 1104. During the second stage 1104, the control circuit 134 may operate the power source 144 to output a sufficient amount of electrical energy to substantially affect or significantly alter biological tissue in conductive communication with the electrosurgical instrument 108 to seal a blood vessel engaged by the electrosurgical instrument 108, for example, according to any of the methods and techniques described in WO 2020 / 227519. For example, the amount of electrical energy delivered to the electrosurgical instrument 108 during the second stage may be higher compared to the amount of electrical energy delivered to the electrosurgical instrument during the first stage 1102, for example, but not limited to, about 13-40 watts, 41-70 watts, or 71-100 watts. The amount of electrical energy delivered to the electrosurgical instrument 108 during the first phase 1102 or the second phase 1104 may depend on various factors, such as the inherent resistance or impedance within various components of the electrosurgical generator 104, the electrosurgical instrument 108, or the electrosurgical device 106 (FIGS. 1-2), the contact area of ​​the electrode(s), electrode plate(s), or other conductive features of the electrosurgical instrument 108, the ability of the control circuit 134 to measure resistance from electrical feedback, the length of the cable coupling the electrosurgical apparatus 106 to the electrosurgical generator 104, etc. Additionally, the amount of electrical energy delivered to the electrosurgical instrument 108 during the first stage 1102 or the second stage 1104, the frequency at which the first stage 1102 is conducted to the second stage 1104, or the type or category of resistance measured may be pre-adjusted or user-adjusted, such as by one or more inputs into the user interface 136 (Figures 1-2) of the electrosurgical generator 104.

[0108] Additionally, the control circuitry 134 may be configured to perform the first stage 1102 continuously or periodically prior to the second stage 1104. For example, a user may select or configure the frequency at which the control circuitry 134 performs the first stage 1102, e.g., relative to the second stage 1104. For example, the control circuitry 134 may perform the first stage 1102 with every actuation of the generator 144, e.g., continuously monitor the thickness of the hydrophobic layer 140 during the electrosurgical procedure. In another example, the control circuitry 134 may perform the first stage 1102 at other intervals, such as every second actuation, every third actuation, or every fourth actuation of the generator 144. Alternatively, the control circuitry 134 may perform the first stage 1102 based on a predetermined or user-selected time interval, e.g., in relation to the total active period of the generator 144 as described above with respect to FIGS. 1-2.

[0109] FIG. 14 illustrates an exemplary graph showing an erosion curve 1200 of the hydrophobic layer 140 as a function of application of electrical energy to the hydrophobic layer 140. FIG. 14 is described with reference to the electrosurgical system 100 shown in and described with reference to FIGS. 1-2. The hydrophobic layer 140 (FIG. 1) may erode linearly, logarithmically, or exponentially, based on, for example, but not limited to, the amount of electrical energy delivered upon each actuation of the generator 144 (FIG. 2), the chemical composition of the hydrophobic layer 140, etc. To aid in monitoring the erosion of the thickness of the hydrophobic layer 140 during the electrosurgical procedure, various points along the erosion curve 1200 that correspond to or otherwise indicate the gradual erosion of the hydrophobic layer 140 can be selectively chosen. For example, as shown in FIG. 14, the erosion curve 1200 may include a starting resistance value 1202, a reference resistance value 1204, a threshold resistance value 1206, and an ending resistance value 1208.

[0110] In some examples, the starting resistance value 1202 can be a predetermined resistance value or range of resistance values ​​associated with the hydrophobic layer 140, e.g., stored in memory 148, and corresponds to a predetermined thickness of the hydrophobic layer 140 (e.g., prior to application of electrical energy to the electrosurgical instrument 108) or is otherwise indicative of a starting thickness of the hydrophobic layer 140. In another example, the starting resistance value 1202 is a measured resistance value, e.g., a first measured resistance value that corresponds to or is otherwise indicative of a starting thickness of the hydrophobic layer 140. The baseline resistance value 1204 can be a resistance value or range of resistance values ​​that corresponds to or is otherwise indicative of a thickness of the hydrophobic layer 140 that is less than the starting thickness, e.g., without limitation, approximately 41-55, 56-70, 71-90 percent of the starting thickness. For example, if the starting resistance 1202 associated with the hydrophobic layer 140 is about 1 ohm, then the baseline resistance 1204 may be, but is not limited to, about 0.41-0.55 ohms, 0.56-0.70 ohms, or 0.71-0.90 ohms. The baseline resistance 1204 may be a resistance value or range of resistance values ​​that corresponds to or is otherwise indicative of a particular thickness of the hydrophobic layer 140 that is less than a thickness associated with the starting resistance 1202, such as, but is not limited to, about 41-55, 56-70, 71-90 percent of the starting thickness. For example, if the starting resistance 1202 associated with the hydrophobic layer 140 is about 1 ohm, then the baseline resistance 1204 may be, but is not limited to, about 0.41-0.55 ohms, 0.56-0.70 ohms, or 0.71-0.90 ohms. The reference resistance value 1204 may be the value at which the operator begins to receive a notification or alarm, for example, an audible or visual warning, as described herein, that the hydrophobic layer 140 is approaching a point of degradation (e.g., a threshold resistance value 1206 at which the coating changes from a first state to a second state and is no longer at a desired level of effectiveness) and therefore the user or operator needs to initiate measures to ensure that the treatment can be completed.

[0111] The threshold resistance 1206 is a resistance value or range of resistance values ​​that corresponds to or is indicative of a thickness of the hydrophobic layer 140 that is less than the thickness associated with the reference resistance 1204, and may be, for example, about 0-10, 11-24, or 25-40 percent of the starting thickness. For example, if the starting resistance 1202 is about 1 ohm, the threshold resistance 1206 may be about 0.1-0.24 ohms, or 0.25-0.40 ohms. In some examples, the threshold resistance 1206 may also correspond to a minimum thickness of the hydrophobic layer 140 before the hydrophobic layer 140 changes from a first state to a second state, as discussed with respect to Figures 8-9 and 12A-12B above. Thus, the threshold resistance 1206 may be a resistance value or range of resistance values ​​at which the control circuit 134 of the electrosurgical generator 104 inhibits activation of the power source 144, for example, to prevent the output of electrical energy to the electrosurgical instrument 108. Thus, in some examples, the control circuit 134 is configured to prevent operation of the power source 144 at or within a range of resistance values ​​leading to the threshold resistance value 1206, e.g., to provide a disable window. The final resistance value 1208 may be a resistance value or range of resistance values ​​that corresponds to or otherwise indicates complete or near complete erosion of the hydrophobic layer 140 from at least a portion of the electrosurgical instrument 108 on which the hydrophobic layer 140 was initially deposited. For example, if the starting resistance value 1202 is approximately 1 ohm, then a resistance value that corresponds to a conductive electrical contact or short within the electrosurgical instrument 108 may be approximately 0 to 0.1 ohms. Thus, in various embodiments, the threshold resistance value 1206 or the final resistance value 1208 may correspond to or otherwise indicate a conductive electrical contact or short within the electrosurgical instrument 108, such as provided by the jaw stop 1012 shown in FIGS. 12A-12B.

[0112] In some examples of operation, processor 150 may receive, retrieve, and / or process instructions or data to cause processor 150 to match or otherwise associate an electrosurgical instrument 108 in electrical communication with electrosurgical generator 104 with data located on memory 148 and / or 152. For example, memory 152 may include identification data associated with electrosurgical instrument 108, and memory 148 may include a library of information associated with a variety of different electrosurgical instruments (such as, but not limited to, those shown in FIGS. 4-7 and 12) and their respective predetermined limits, such as defined by threshold resistance value 1206 or final resistance value 1208, or be in network communication. In such examples, processor 150 may receive, retrieve, and / or process instructions or data to cause processor 150 to obtain the identification data from memory 152 of electrosurgical instrument 108 when electrosurgical instrument 108 is connected to electrosurgical generator 104. The processor 150 may then receive, retrieve, and / or process instructions or data to retrieve an individual data set (e.g., a database entry) that defines or otherwise includes any of the starting resistance value 1202, the baseline resistance value 1204, the threshold resistance value 1206, and the final resistance value 1208 of the electrosurgical instrument 108, for example, by matching the identification data of the electrosurgical instrument 108 with associated data stored in the memory 148. In another example, the processor 150 may receive, retrieve, and / or process instructions or data to cause the processor 150 to retrieve any of the starting resistance value 1202, the baseline resistance value 1204, the threshold resistance value 1206, or the final resistance value 1208 of the electrosurgical instrument 108 directly from the memory 152 of the electrosurgical instrument 108. The processor 150 may also receive, retrieve, and / or process instructions or data to cause the transceiver to wirelessly receive or transmit data to or from the memory 148 using any of a variety of wireless protocols, such as those described with respect to FIG. 2 above. Thus, the control circuit 134 may be configured to identify, for example, a starting resistance value 1202, a reference resistance value 1204, a threshold resistance value 1206, or a final resistance value 1208, or various other predetermined resistance values ​​along the erosion curve 1200 or the erosion curve of other erodible coatings.

[0113] The electrosurgical generator 104 may be configured to monitor the thickness of the hydrophobic layer 140 during an electrosurgical procedure. For example, the processor 150 may receive, retrieve, and / or process instructions or data to cause the processor 150 to control the measurement circuitry 146 to activate the power source 144 to measure at least one resistance value associated with biological tissue, such as when the first and second electrode plates 1008, 1010 of Figures 12A-12B are in contact with each other or with at least one of the jaw stops 1012, or when at least one of the jaw stops 1012 of the first jaw 1004 is in contact with at least one of the jaw stops of the second jaw 1006, or when biological tissue is in conductive communication with at least the first and second electrode plates 1008, 1010. In some examples, the processor 150 may receive, retrieve, and / or process instructions or data to control the measurement circuit 146 and the power source 144 to measure a plurality of resistance values ​​associated with the hydrophobic layer 1002 over a predetermined period of time, such as a period stored in the memory 148, or selected during the procedure, such as selectable via one or more user inputs to the user interface 136. In such examples, the processor 150 may receive, retrieve, and / or process instructions or data to calculate an average measured resistance value from the plurality of measured resistance values ​​and help improve the accuracy of the measured resistance value available for comparison to the reference resistance value 1204, the threshold resistance value 1206, or the final resistance value 1208.

[0114] In another example, such as when biological tissue is in conductive communication with the electrosurgical instrument 1000 (e.g., located between and in contact with a first electrode plate 1008 (FIGS. 12A-12B) and a second electrode plate 1010 (FIGS. 12A-12B)), the processor 150 may receive, retrieve, and / or process instructions or data to cause the processor 150 to subtract a measured resistance value associated with the biological tissue 102 from a starting resistance value 1202 of the hydrophobic layer 140. The processor 150 may receive, retrieve, and / or process instructions or data to cause the processor 150 to calculate a change (e.g., delta) between the starting resistance value 1202 and the remainder of subtracting the measured resistance value associated with the biological tissue 102 from the starting resistance value 1202 to obtain a measured resistance value associated with the hydrophobic layer 140. The processor 150 can then receive, retrieve and / or process instructions or data to cause the processor 150 to compare the measured resistance value associated with the hydrophobic layer 140 to either the baseline resistance value 1204, the threshold resistance value 1206, or the final resistance value 1208 after each actuation of the power source 144, or at other intervals, including but not limited to the number of actuations of the power source 144, or predetermined or configured time windows during treatment implemented by the processor 150 in response to one or more user inputs to the user interface 136.

[0115] For example, if the measured resistance and starting resistance 1202 associated with hydrophobic layer 140 is equal to or greater than either the baseline resistance 1204 or the threshold resistance 1206, control circuit 134 may determine that hydrophobic layer 140 has not eroded to a minimum thickness or changed from a first state to a second state. In response, processor 150 may receive, retrieve and / or process instructions or data and thereafter operate or enable operation of power source 144 to output electrical energy to electrosurgical instrument 108, as described with respect to FIG. If the measured resistance value is less than or equal to any of the reference resistance value 1204, the threshold resistance value 1206, or the final resistance value 1208, the processor 150 may receive, retrieve and / or process instructions or data and cause the processor 150 to block or otherwise prevent subsequent operation of the power source 144, for example, by interrupting signal communication between the power source 144 and the electrosurgical device 106 or any input device of the electrosurgical system 100, such as the user interface 136, until a different (e.g., unexpired) electrosurgical instrument 108 is connected to the electrosurgical generator 104.

[0116] Additionally, if a predetermined limit of the electrosurgical instrument 108 is exceeded, such as if at least one measured resistance value is less than or equal to the threshold resistance value 1206 or the final resistance value 1208, the control circuitry 134 may be configured to transfer data to memory 152 to prevent subsequent reuse of the electrosurgical instrument 108 after the electrosurgical procedure is completed. For example, if the electrosurgical instrument 108 is later reprocessed and coupled to a different electrosurgical generator, the processor 150 may receive, retrieve and / or process instructions or data, causing the processor 150 to receive (e.g., read) the data stored on the memory 152 and, in response, inhibit operation of the power source 144 to prevent electrical energy from being output to the electrosurgical instrument 108.

[0117] The control circuitry 134 may further be configured to start a timer or count the number of subsequent activations of the power source 144 if at least one measured resistance value associated with the hydrophobic layer 140 is less than or equal to the reference resistance value 1204 or greater than the threshold resistance value 1206, such as by a predetermined percentage or number, and to prevent activation of the power source 144 after a time window has elapsed or a certain number of activations of the power source 144 have occurred. For example, the processor 150 may receive, retrieve, and / or process instructions or data, and count and store on the memory 148 or 152 the number of seconds or minutes, or a total number of subsequent activations of the power source 144, after the control circuitry 134 has determined that the measured resistance value associated with the hydrophobic layer 140 is less than or equal to the reference resistance value 1204 or the threshold resistance value 1206. This may, for example, prevent reuse of an expired electrosurgical instrument after an electrosurgical procedure has concluded, while at the same time allowing the user to continue to apply electrical energy to tissue in situations where a replacement instrument is not immediately available to the user or where mid-procedure replacement of the instrument is difficult or impractical.

[0118] The control circuitry 134 may be configured to cause the user interface 136 to output an audible or visual alert when a timer starts or when beginning to count the total number of activations of the power source 144. For example, the processor 150 may receive, retrieve, and / or process instructions or data to cause the user interface 136 to generate and output an audible or visual alert to a user, as shown in FIG. 3 and described further with respect thereto. Such an audible or visual alert may correspond to a determination made by the processor 150 that a measured resistance value associated with the hydrophobic layer 140 is less than or equal to either the baseline resistance value 1204, the threshold resistance value 1206, or the final resistance value 1208. In some examples, such an audible or visual alert may correspond to a user selected resistance value or delta between the starting resistance value 1202 and the measured resistance value associated with the hydrophobic layer 140, configured by, for example, one or more user inputs to the user interface 136.

[0119] 15 shows a flow chart of an exemplary method 1300 for controlling the output of electrical energy from an electrosurgical generator to an interconnected electrosurgical instrument based on the thickness of an erodible coating deposited on the electrosurgical instrument. The steps or operations of method 1300 are shown in a particular order for convenience and clarity. The operations described may be performed in parallel or in a different order without significantly affecting other operations. As illustrated, method 1300 includes operations that may be performed by multiple different actors, devices, and / or systems. It is understood that a subset of the operations discussed in method 1300 may be attributable to a single actor device or system and may be considered a separate stand-alone process or method.

[0120] The method 1300 may begin at operation 1302. Operation 1302 includes measuring at least one resistance value corresponding to a thickness of the erodible coating. For example, a user, such as a surgeon or clinician, may initiate delivery of electrical energy to biological tissue in contact with an electrode or electrode plate of an electrosurgical instrument having an erodible coating deposited thereon to obtain a measured resistance value associated with the erodible coating. In another example, a user, such as a surgeon or clinician, may initiate delivery of electrical energy to an electrosurgical instrument having an erodible coating deposited thereon to obtain a measured resistance value associated with both the erodible coating and the biological tissue. In another example, a user, such as a surgeon or clinician, may initiate delivery of electrical energy to biological tissue in contact with an electrode or electrode plate of an electrosurgical instrument having an erodible coating deposited thereon to first obtain a measured resistance value associated with the erodible coating. A control circuit of the electrosurgical generator may then subtract the measured resistance value associated with the biological tissue from a predetermined starting resistance value of the erodible coating. The control circuit can then calculate a delta between the remainder of the measured resistance value associated with the biological tissue subtracted from a predetermined starting resistance value of the erodible coating to obtain a measured resistance value associated with the erodible coating, e.g., indicative of the resistance or impedance to the passage of electrical energy through the biological tissue contributed or caused by the erodible coating.

[0121] Operation 1302 may optionally initially include obtaining a threshold resistance value by exchanging information between a memory of the electrosurgical generator or an RFID or NFC transceiver and a memory of the electrosurgical instrument or an RFID or NFC tag, respectively. For example, connecting the electrosurgical instrument to the electrosurgical generator may power the RFID or NFC tag to enable wireless data transmission or reception, for example, between the RFID or NFC transceiver and the RFID or NFC tag.

[0122] Operation 1302 may include pivoting the first jaw and the second jaw from an open position to a closed position to engage biological tissue located therebetween. For example, a user may manipulate a gripping lever of an electrosurgical device including an electrosurgical instrument by moving the gripping lever proximally toward a handle of the electrosurgical device, thereby pivoting the first jaw toward the second jaw and simultaneously contacting at least one of the first jaw or the second jaw with biological tissue located between the first jaw and the second jaw. Operation 1302 may include pivoting the first jaw and the second jaw from an open position to a closed position to contact a first electrode plate located on the first jaw with a second electrode plate located on the second jaw. For example, a user may operate a gripping lever of an electrosurgical device including an electrosurgical instrument by moving it proximally toward a handle of the electrosurgical device, thereby pivoting a first jaw toward a second jaw and simultaneously contacting the first electrode plate with the second electrode plate.

[0123] Method 1300 may include operation 1304. Operation 1304 may include comparing at least one measured resistance value to a threshold resistance value corresponding to a minimum thickness of the erodible coating before the erodible coating changes from a first state to a second state. For example, a control circuit of the electrosurgical generator may compare the at least one measured resistance value associated with the erodible coating to a reference or threshold resistance value associated with the gradual erosion of the erodible coating. Operation 1304 may include comparing the at least one measured resistance value to the threshold resistance value performed by the electrosurgical generator upon each activation of the generator. For example, a control circuit of the electrosurgical generator may cause the at least one measured resistance value associated with the erodible coating to be compared to the threshold resistance value upon each activation of the generator or at other intervals, including but not limited to, a number of activations of the generator, or a time window implemented by a processor, predetermined or set during a procedure, for example, in response to one or more user inputs to a user interface of the electrosurgical generator.

[0124] Method 1300 may optionally include operation 1306. Operation 1306 includes calculating an average resistance value from a plurality of measured resistance values, where at least one measured resistance value is the average resistance value. For example, the control circuitry may control the measurement circuitry and power source of the electrosurgical generator to measure a plurality of resistance values ​​associated with the biological tissue 102 over or during a predetermined or selected period or time window during the procedure. In such an example, the control circuitry may calculate the average measured resistance value from the plurality of measured resistance values ​​to help improve accuracy of the measured resistance value relative to actual erosion of the erodible coating.

[0125] Method 1300 may include operation 1308. Operation 1308 may include determining that the erodible coating has eroded to a minimum thickness if the measured resistance value is less than or equal to a threshold resistance value. For example, the control circuitry of the electrosurgical generator may calculate the difference between the measured resistance value and the threshold resistance value and determine whether the measured resistance value is greater than, equal to, or less than the threshold resistance value based on the difference between the measured resistance value and the threshold resistance value.

[0126] Operation 1308 may include storing information in a memory of the electrosurgical instrument or in an RFID or NFC tag indicating that the erodible coating has eroded to a minimum thickness. For example, after the control circuitry determines that the erodible coating has eroded to a minimum thickness, the control circuitry may store an indication that the erodible coating has eroded to a minimum thickness in a memory of the electrosurgical generator or the electrosurgical instrument. In some examples, the electrosurgical generator may include a radio frequency identification (RFID) or near field communication (NFC) wireless transceiver, and the electrosurgical instrument may include an inlay or hard tag including, for example, an antenna and memory, enabling wireless data transmission and reception between, for example, the RFID or NFC transceiver and the RFID or NFC tag. Operation 1308 may include generating an audible or visual alert indicating that the erodible coating has eroded to a minimum thickness. For example, the control circuitry may cause a user interface of the electrosurgical generator to generate and output an audible or visual alert upon determining that the erodible coating has eroded to a minimum thickness.

[0127] Operation 1308 may include starting a timer before the minimum thickness is reached to prevent the electrosurgical generator from preventing activation of the source when the time window has elapsed. For example, a processor in the electrosurgical generator's control circuitry may receive, retrieve, and / or process instructions or data and count and store in the memory of the electrosurgical generator the number of seconds or minutes after the control circuitry determines that the measured resistance value associated with the erodible coating is less than or equal to a reference resistance value, e.g., which is greater than a threshold resistance value corresponding to a minimum thickness of the erodible coating.

[0128] Method 1300 may optionally include operation 1310. Operation 1310 includes measuring at least one resistance value corresponding to a conductive electrical contact or short at a jaw stop in the electrosurgical instrument. For example, the jaw stop may include at least two conductive elements disposed thereon, otherwise contained therein, or integrated therewith that may be configured to create a conductive electrical contact or short that is detectable by a processor of the electrosurgical generator's control circuit when at least a portion of an erodible coating deposited on the jaw stop erodes to a minimum thickness of the erodible coating.

[0129] Method 1300 may include operation 1312. Operation 1312 may include blocking activation of a power source of the electrosurgical generator to prevent output of electrical energy to the electrosurgical instrument. For example, the control circuitry of the electrosurgical generator may disable the power source by blocking or otherwise preventing the electrosurgical instrument from effectively requesting activation via operation of an energy button of an electrosurgical device that includes the electrosurgical instrument, or by blocking or otherwise preventing electrical energy generated upon activation of the power source from being output to the electrosurgical instrument by interrupting signal communication between the electrosurgical device and the power source of the electrosurgical generator.

[0130] The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of example, specific embodiments in which the invention may be practiced. These embodiments are also referred to herein as "examples." Such examples may include elements in addition to those shown or described. However, the inventor also contemplates examples in which only those elements shown or described are provided. Furthermore, the inventor also contemplates examples in which any combination or permutation of those elements (or one or more aspects thereof) shown or described is used either with a particular example (or one or more aspects thereof) or with another example (or one or more aspects thereof) shown or described herein. In the event of a conflict in usage between this document and any document incorporated by reference, the usage in this document controls.

[0131] In this document, the terms "a" or "an" are used to include one or more, as is common in patent documents, regardless of any other examples or the use of "at least one" or "one or more." In this document, the term "or" is used to refer to an inclusive or, unless otherwise indicated, "A or B" includes "A but not B," "B but not A," and "A and B." In this document, the terms "including" and "in which" are used as the plain English equivalents of the respective terms "comprising" and "wherein." Also, in the claims that follow, the terms "including" and "comprising" are open-ended, i.e., systems, devices, articles, compositions, formulations, or processes that include elements in addition to those listed after such terms in the claims are still considered to be within the scope of the claims. Moreover, in the claims that follow, the terms "first," "second," and "third," etc. are used merely as labels and are not intended to impose numerical requirements on their objects.

[0132] Examples of the methods described herein may be at least partially machine or computer implemented. Some examples may include computer readable or machine readable media encoded with instructions operable to configure an electronic device to perform the methods described in the above examples. An implementation of such a method may include code, such as microcode, assembly language code, high level language code, etc. Such code may include computer readable instructions for performing various methods. The code may form part of a computer program product. Further, in one example, the code may be tangibly stored on one or more volatile, non-transitory, or non-volatile tangible computer readable media, such as during execution or at other times. Examples of these tangible computer readable media may include, but are not limited to, hard disks, removable magnetic disks, removable optical disks (e.g., compact disks and digital video disks), magnetic cassettes, memory cards or sticks, random access memory (RAM), read only memory (ROM), etc.

[0133] The above description is intended to be illustrative and not restrictive. For example, the foregoing examples (or one or more aspects thereof) may be used in combination with each other. Alternative embodiments may be used, such as upon review of the above description by one of ordinary skill in the art. The Summary is provided in compliance with 37 C.FR Section 1.72(b) to allow the reader to quickly ascertain the nature of the technical disclosure. The Summary is presented with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Also, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be construed as an intention that any unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may lie in less than all features of a particular disclosed embodiment. Thus, the following claims are hereby incorporated into the Detailed Description as an example or embodiment, with each claim standing on its own as a separate embodiment, and it is contemplated that such embodiments may be combined with each other in various combinations and permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

[0134] Notes and Examples The following non-limiting examples detail particular aspects of the present subject matter that, among other things, solve the problems and provide the benefits discussed herein.

[0135] Example 1 is an electrosurgical generator configured to generate electrical energy for application to biological tissue via electrical communication with an electrosurgical instrument, the electrosurgical generator including a power source configured to operate to output electrical energy to the electrosurgical instrument, a measurement circuit configured to measure a resistance value associated with an erodible coating deposited on a portion of the electrosurgical instrument, and a control circuit in communication with the power source and the measurement circuit, the control circuit configured to compare the measured resistance value of the erodible coating to a threshold resistance value for the coating, and to control operation of the power source based on a comparison of the measured resistance value to the threshold resistance value.

[0136] In Example 2, the subject matter of Example 1 includes the threshold resistance value corresponding to a known resistance value that corresponds to a thickness of the erodible coating before the erodible coating changes from a first state to a second state, or a previously measured resistance value that represents a starting resistance value of the coating.

[0137] In Example 3, the subject matter of Example 2 includes the erodible coating having a surface adhesion to biological tissue in a first state that is less than the surface adhesion to biological tissue of a material of the portion of the electrosurgical instrument on which the coating is deposited.

[0138] In Example 4, the subject matter of Examples 1-3 includes where the erodible coating is a non-stick hydrophobic layer selected from one of polydimethylsiloxane, hexadimethyldisiloxane, and tetramethyldisiloxane.

[0139] In example 5, the subject matter of examples 1-4 includes, wherein the measured resistance value and the threshold resistance value are indicative of at least one of a resistance, an impedance, or a phase angle, and the control circuit is configured to compare the measured resistance value to the threshold resistance value upon each actuation of the power supply.

[0140] In Example 6, the subject matter of Examples 1-5 includes, wherein the control circuit is configured to control operation of the power supply by preventing operation of the power supply when the measured resistance value is less than or equal to a threshold resistance value.

[0141] In Example 7, the subject matter of Example 6 includes the electrosurgical generator including a user interface in electrical communication with the control circuit, the control circuit configured to cause the user interface to output an audible or visual warning when preventing operation of the power source.

[0142] In Example 8, the subject matter of Examples 1-7 includes the electrosurgical generator including a user interface in electrical communication with the control circuit, the control circuit configured to cause the user interface to output an audible or visual alert when the measured resistance value is less than or equal to a reference resistance value, the reference resistance value being greater than a threshold resistance value.

[0143] In example 9, the subject matter of examples 1-8 includes, wherein the control circuit is configured to start a timer when the measured resistance is greater than or equal to a threshold resistance by a predetermined percentage, and to prevent operation of the power supply after the timer has elapsed.

[0144] In Example 10, the subject matter of Example 9 includes, wherein the electrosurgical generator includes a user interface in electrical communication with the control circuit, and the control circuit is configured to cause the user interface to output an audible or visual warning upon starting the timer.

[0145] In example 11, the subject matter of examples 1-10 includes, where the control circuit is configured to count the number of activations of the power supply when the measured resistance value is greater than or equal to a threshold resistance value, and to prevent activation of the power supply after the threshold number of activations of the power supply have occurred.

[0146] In example 12, the subject matter of examples 1-11 includes, wherein the measured resistance value is an average value of a plurality of measured resistance values, and the control circuitry is configured to store the plurality of measured resistance values ​​and periodically calculate the average value from the plurality of measured resistance values.

[0147] In Example 13, the subject matter of Examples 1-12 includes the control circuit being in electrical communication with a database including a plurality of database entries each defining a threshold resistance value for a different electrosurgical instrument, and the electrosurgical instrument including a memory containing data matchable by the control circuit to an individual database entry.

[0148] In Example 14, the subject matter of Examples 1-13 includes, wherein the threshold resistance value is a resistance value corresponding to a conductive electrical contact or short within the electrosurgical instrument when the erodible coating has eroded to a thickness of the erodible coating before the erodible coating changes from a first state to a second state, or a previously measured resistance value representing a starting resistance value of the coating.

[0149] Example 15 is an electrosurgical system including an electrosurgical instrument configured to apply electrical energy to biological tissue, an electrosurgical generator for supplying electrical energy to the electrosurgical instrument, the electrosurgical generator including an electrical connector configured to electrically couple the electrosurgical instrument to the electrosurgical generator, a power source configured to operate to output electrical energy to the electrosurgical instrument, a measurement circuit configured to measure a resistance value associated with erosion of an erodible coating deposited on a portion of the electrosurgical instrument due to operation of the power source, and a control circuit including a generator component disposed within the electrosurgical generator and an instrument component disposed within the electrosurgical instrument, the control circuit configured to compare the measured resistance value of the erodible coating to a threshold resistance value of the coating and to control operation of the power source based on a comparison of the measured resistance value to the threshold resistance value.

[0150] In example 16, the subject matter of example 15 includes wherein the generator component is a control circuit memory or an RFID or NFC transceiver and the equipment component is a programmable memory or an RFID or NFC tag, respectively.

[0151] In Example 17, the subject matter of Examples 15-16 includes the following: the erodible coating includes a non-stick coating configured to prevent adhesion of tissue to the electrosurgical instrument, the erodible coating is configured to erode in thickness, the threshold resistance value corresponds to a minimum thickness of the erodible coating before the erodible coating changes from a first state to a second state, and the control circuit is configured to store information regarding an instrument component or generator component associated with the minimum thickness.

[0152] In Example 18, the subject matter of Example 17 includes the electrosurgical instrument being a forceps including a first jaw and a second jaw pivotable between an open position and a closed position, the first jaw including a jaw stop extending outwardly from the first jaw toward the second jaw, the jaw stop being in electrical communication with the control circuit and configured to contact the second jaw when the first jaw and the second jaw are in the closed position, and an erodible coating being deposited on at least one of the jaw stop, along a portion of the first jaw, and along a portion of the second jaw.

[0153] In Example 19, the subject matter of Example 18 includes a plurality of jaw stops spaced laterally apart from one another along the first jaw portion, at least one of the plurality of jaw stops being in electrical communication with the control circuit, and at least one of the plurality of jaw stops being electrically insulating.

[0154] In Example 20, the subject matter of Example 19 includes, wherein the measured resistance value is an average value of a plurality of measured resistance values ​​measured at a first jaw stop in electrical communication with the control circuit, and the control circuit is configured to calculate the average value from the measured resistance values.

[0155] In Example 21, the subject matter of Examples 18-20 includes wherein the threshold resistance value is a resistance value corresponding to a conductive electrical contact or short within the electrosurgical instrument, and the jaw stop includes a plurality of conductive strands extending between the first jaw and a distal surface of the jaw stop, and the conductive strands are configured to cause a conductive electrical contact or short within the electrosurgical instrument when the erodible coating erodes to a minimum thickness.

[0156] Example 22 is a method for controlling output of electrical energy from an electrosurgical generator to an interconnected electrosurgical instrument based on a thickness of an erodible coating deposited on the electrosurgical instrument, the method including measuring at least one resistance value corresponding to a thickness of the erodible coating, comparing the at least one measured resistance value to a threshold resistance value corresponding to a minimum thickness of the erodible coating before the erodible coating changes from a first state to a second state, determining that the erodible coating has eroded to a minimum thickness if the measured resistance value is equal to or less than the threshold resistance value, and inhibiting operation of a power source of the electrosurgical generator to prevent electrical energy from being output to the electrosurgical instrument.

[0157] In Example 23, the subject matter of Example 22 includes the method including first obtaining a threshold resistance value by exchanging information between a memory or an RFID or NFC transceiver of the electrosurgical generator and a memory or an RFID or NFC tag of the electrosurgical instrument, respectively.

[0158] In Example 24, the subject matter of Examples 22-23 includes where comparing the at least one measured resistance value to a threshold resistance value is performed by the electrosurgical generator upon each actuation of the generator.

[0159] In Example 25, the subject matter of Examples 22-24 includes where comparing the at least one measured resistance value to a threshold resistance value includes calculating an average resistance value from the plurality of measured resistance values, and the at least one measured resistance value is the average resistance value.

[0160] In Example 26, the subject matter of Examples 22-25 includes, wherein determining that the erodible coating has eroded to a minimum thickness includes storing information indicative of the erodible coating having eroded to a minimum thickness in a memory of the electrosurgical instrument or in an RFID or NFC tag.

[0161] In Example 27, the subject matter of Examples 22-26 includes where determining that the erodible coating has eroded to a minimum thickness includes generating an audible or visual warning.

[0162] In Example 28, the subject matter of Examples 22-27 includes determining that the erodible coating has eroded to a minimum thickness includes starting a timer before the minimum thickness is reached to prevent the electrosurgical generator from preventing operation of the power source when the time window has elapsed.

[0163] In Example 29, the subject matter of Examples 22-28 includes where measuring at least one resistance value includes pivoting the first jaw and the second jaw from an open position to a closed position to engage biological tissue located therebetween.

[0164] In Example 30, the subject matter of Examples 22-29 includes where measuring at least one resistance value includes pivoting the first jaw and the second jaw from an open position to a closed position to contact a first electrode plate disposed on the first jaw with a second electrode plate disposed on the second jaw.

[0165] In Example 31, the subject matter of Examples 22-30 includes where determining that the erodible coating has eroded to a minimum thickness includes measuring at least one resistance value corresponding to a conductive electrical contact or short at a jaw stop in the electrosurgical instrument.

[0166] Example 32 is at least one machine-readable medium containing instructions that, when executed by a processing circuit, cause the processing circuit to perform operations to implement any of Examples 1-31.

[0167] Example 33 is an apparatus including means for carrying out any one of Examples 1 to 31.

[0168] The thirty-fourth embodiment is a system for carrying out any one of the first to thirty-first embodiments.

[0169] Example 35 is a method for carrying out any of Examples 1-31.

Claims

[Claim 1] 1. An electrosurgical generator configured to generate electrical energy for application to biological tissue via electrical communication with an electrosurgical instrument, a power source configured to operate to output the electrical energy to the electrosurgical instrument; a measurement circuit configured to measure a resistance value associated with an erodible coating deposited on a portion of the electrosurgical instrument; a control circuit in communication with the power source and the measurement circuit, comparing the measured resistance of the erodible coating to a threshold resistance of the coating; a control circuit configured to control operation of the power supply based on the comparison of the measured resistance value to the threshold resistance value; 1. An electrosurgical generator comprising:

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