Electrosurgical devices, methods of use, and methods of manufacture

Abstract

In one example, the electrosurgical instrument includes a housing, an electrosurgical electrode extending from a distal end of the housing, and an electrical cable extending from a proximal end of the housing. The electrical cable includes (I) a plug configured to electrically couple to an electrosurgical generator, (II) a proximal cable including a plurality of first conductors extending from the plug to a battery module, and (III) a distal cable including a plurality of second conductors extending from the battery module to the housing. The battery module includes (a) a casing configured to receive a battery, and (b) a power driver circuit in an interior compartment of the casing. The power driver circuit includes (i) a first set of contacts electrically coupled to the first conductors, (ii) a second set of contacts electrically coupled to the second conductors, and (iii) a third set of contacts electrically coupled to the battery.

Description

[Technical field]

[0001] The present disclosure relates generally to electrosurgical devices and, more particularly, to electrosurgical devices and methods for supplying electrosurgical energy and direct current (DC) power during electrosurgical procedures.

[0002] [Related Applications] This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 290,492, filed December 16, 2021, the entire contents of which are incorporated herein by reference in their entirety. [Background technology]

[0003] Electrosurgery involves the application of radio frequency (RF) electrical current (also referred to as electrosurgical energy) to biological tissue to cut, coagulate, or otherwise modify the tissue during electrosurgical procedures. Specifically, an electrosurgical generator generates an electrical current and provides this current to an active electrode. The active electrode applies the current (and therefore power) to the tissue. The current passes through the tissue and returns to the generator via a return electrode (also referred to as a dispersive electrode). As the current passes through the tissue, the impedance of the tissue converts a portion of the current into thermal energy (e.g., via the principles of resistive heating), which increases the temperature of the tissue and causes the tissue to be modified (e.g., cut, coagulate, ablate, and / or seal). Summary of the Invention

[0004] In one example, the electrosurgical instrument includes a housing, an electrosurgical electrode extending from a distal end of the housing, and an electrical cable extending from a proximal end of the housing. The electrical cable includes (I) a plug configured to electrically couple to an electrosurgical generator, (II) a proximal cable including a plurality of first conductors extending from the plug to a battery module, and (III) a distal cable including a plurality of second conductors extending from the battery module to the housing. The battery module includes (a) a casing configured to receive a battery, and (b) a power driver circuit in an interior compartment of the casing. The power driver circuit includes (i) a first set of contacts electrically coupled to the first conductors, (ii) a second set of contacts electrically coupled to the second conductors, and (iii) a third set of contacts electrically coupled to the battery.

[0005] In another example, a method of operating an electrosurgical instrument includes coupling the electrosurgical instrument to an electrosurgical generator. The electrosurgical instrument includes a housing, an electrosurgical electrode extending from a distal end of the housing, and an electrical cable extending from a proximal end of the housing. The electrical cable includes (I) a plug configured to electrically couple to the electrosurgical generator, (II) a proximal cable including a plurality of first conductors extending from the plug to a battery module, and (III) a distal cable including a plurality of second conductors extending from the battery module to the housing. The battery module includes (a) a casing configured to receive a battery, and (b) a power driver circuit in an interior compartment of the casing. The power driver circuit includes (i) a first set of contacts electrically coupled to the first conductors, (ii) a second set of contacts electrically coupled to the second conductors, and (iii) a third set of contacts electrically coupled to the battery.

[0006] The method also includes transmitting electrosurgical energy from the electrosurgical generator to the electrosurgical electrode via the proximal and distal cables. In addition, the method includes performing an electrosurgical procedure using the electrosurgical energy at the electrosurgical electrode. The method further includes transmitting direct current (DC) power from a battery to a DC powered device.

[0007] In another example, a method of forming an electrosurgical instrument includes forming a housing extending from a proximal end to a distal end and coupling an electrosurgical electrode to the distal end of the housing. The electrosurgical electrode is configured to use electrosurgical energy to at least one of cut or coagulate tissue.

[0008] The method also includes forming an electrical cable configured to deliver electrosurgical energy from the electrosurgical generator. The electrical cable includes (I) a plug configured to electrically couple to the electrosurgical generator, (II) a proximal cable including a plurality of first conductors extending from the plug to a battery module, and (III) a distal cable including a plurality of second conductors extending from the battery module to a housing. The battery module includes (a) a casing configured to receive a battery, and (b) a power driver circuit in an interior compartment of the casing. The power driver circuit includes (i) a first set of contacts electrically coupled to the first conductors, (ii) a second set of contacts electrically coupled to the second conductors, and (iii) a third set of contacts electrically coupled to the battery.

[0009] In another example, an electrosurgical instrument includes a housing extending from a proximal end to a distal end and an electrosurgical electrode extending from the distal end of the housing. The electrosurgical electrode is configured to use electrosurgical energy to at least one of cut or coagulate tissue. The electrosurgical instrument also includes an electrical cable extending from the proximal end of the housing. The electrical cable is configured to deliver electrosurgical energy from an electrosurgical generator.

[0010] The electrical cable includes a plug configured to electrically couple to an electrosurgical generator and a battery module. The battery module includes (i) a casing defining an internal compartment configured to receive a battery, and (ii) a battery printed circuit board (PCB) in the internal compartment of the casing, the battery PCB including a first set of contacts configured to electrically couple the battery to the battery PCB. The electrical cable also includes a proximal cable extending from the plug to the battery module, a distal cable extending from the battery module to the housing, a plurality of electrosurgical energy (ES energy) conductors extending the entire length of the electrical cable between the plug and the housing, and a plurality of direct current power (DC power) conductors extending from the battery PCB to the housing.

[0011] In another example, a method of operating an electrosurgical instrument includes coupling the electrosurgical instrument to an electrosurgical generator. The electrosurgical instrument includes a housing, an electrosurgical electrode extending from a distal end of the housing, and an electrical cable extending from a proximal end of the housing. The electrical cable includes a plug configured to electrically couple to the electrosurgical generator and a battery module. The battery module includes (i) a casing defining an internal compartment configured to receive a battery, and (ii) a battery printed circuit board (PCB) in the internal compartment of the casing, the battery PCB including a first set of contacts configured to electrically couple the battery to the battery PCB. The electrical cable also includes a proximal cable extending from the plug to the battery module, a distal cable extending from the battery module to the housing, a plurality of electrosurgical energy (ES energy) conductors extending the entire length of the electrical cable between the plug and the housing, and a plurality of direct current power (DC power) conductors extending from the battery PCB to the housing.

[0012] The method also includes transmitting electrosurgical energy from the electrosurgical generator to the electrosurgical electrode via the proximal and distal cables. In addition, the method includes performing an electrosurgical procedure using the electrosurgical energy at the electrosurgical electrode. The method further includes transmitting direct current (DC) power from a battery to a DC powered device.

[0013] In another example, a method of forming an electrosurgical instrument includes forming a housing extending from a proximal end to a distal end and coupling an electrosurgical electrode to the distal end of the housing. The electrosurgical electrode is configured to use electrosurgical energy to at least one of cut or coagulate tissue.

[0014] The method also includes forming an electrical cable configured to deliver electrosurgical energy from an electrosurgical generator. The electrical cable includes a plug configured to electrically couple to the electrosurgical generator and a battery module. The battery module includes (i) a casing defining an internal compartment configured to receive a battery, and (ii) a battery printed circuit board (PCB) in the internal compartment of the casing, the battery PCB including a first set of contacts configured to electrically couple the battery to the battery PCB. The electrical cable also includes a proximal cable extending from the plug to the battery module, a distal cable extending from the battery module to the housing, a plurality of electrosurgical energy (ES energy) conductors extending the entire length of the electrical cable between the plug and the housing, and a plurality of direct current power (DC power) conductors extending from the battery PCB to the housing.

[0015] The novel features characteristic of the embodiments are set forth in the appended claims, however the embodiments, as well as the preferred mode of use, further objects and explanations thereof, will be best understood by reference to the following detailed description of the embodiments of the present disclosure, read in conjunction with the accompanying drawings. [Brief description of the drawings]

[0016] [Figure 1] 1 is a simplified block diagram of an electrosurgical system, according to one example. [Diagram 2] 1 is a perspective view of an electrosurgical instrument according to another example. [Diagram 3] 2 is a simplified block diagram of an electrical cable for the electrosurgical system of FIG. 1, according to one example. [Figure 4A] FIG. 2 is a perspective view of a battery module in an open state according to an example. [Figure 4B] FIG. 4B is a first side view of the battery module of FIG. 4A in a closed state, according to an example. [Figure 4C] FIG. 4B is a second side view of the battery module of FIG. 4A in a closed state, according to an example. [Figure 4D] FIG. 2 is a side view of a battery module in an open state, according to an example. [Figure 4E] FIG. 4B is a perspective view of the power driver circuit shown in FIG. 4A, according to an example. [Figure 4F] FIG. 4F is a bottom view of the power driver circuit shown in FIG. 4E, according to an example. [Diagram 5] FIG. 4 is a perspective view of the battery module of FIGS. 1 to 3 according to another example. [Figure 6] FIG. 2 is a simplified block diagram of an electrical cable for the electrosurgical system of FIG. 1, according to another example. [Figure 7A] FIG. 7 illustrates an implementation of the electrical cable shown in FIG. 6, according to an example. [Figure 7B] FIG. 7B is a cross-sectional view of the electrical cable shown in FIG. 7A, according to an example. [Figure 8A] FIG. 2 is a top view of the interior compartment of the casing of a battery module in an open state, according to an example. [Figure 8B] FIG. 8B is a bottom view of the outer surface of the casing shown in FIG. 8A in an open state, according to an example. [Figure 8C] FIG. 8B is a first side view of the casing shown in FIG. 8A in an open state, according to an example. [Figure 8D] 8B is a side view of the distal end of the casing shown in FIG. 8A in an open state, according to an example. [Figure 8E] 8B is a side view of the proximal end of the casing shown in FIG. 8A in an open state, according to one example. [Figure 9] 1 is a flow diagram of a process for operating an electrosurgical instrument, according to one example. [Figure 10] FIG. 13 is a flow diagram of a process for forming an electrosurgical instrument, according to one example. [Figure 11] 1 is a flow diagram of a process for operating an electrosurgical instrument, according to one example. [Figure 12] FIG. 13 is a flow diagram of a process for forming an electrosurgical instrument, according to one example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0017] The disclosed examples will now be described in more detail below with reference to the accompanying drawings, in which some, but not all, of the disclosed examples are shown. Indeed, several different examples may be described, and should not be construed as being limited to the examples described herein. Rather, these examples are described so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.

[0018] When the terms "approximately" or "substantially" are used with reference to a quantity or measurement described herein, it means that the characteristic, parameter, or value referred to need not be exactly achieved, but rather that deviations or variations including, for example, tolerances, measurement errors, limitations of measurement precision, and other factors known to those of skill in the art may occur to an extent that does not preclude the effect that the characteristic is intended to have.

[0019] As mentioned above, the electrosurgical instrument may use electrical energy supplied by an electrosurgical generator to apply electrosurgical energy from the electrosurgical electrodes to tissue. In some instances, it may be beneficial to operate a direct current (DC) powered device before, during, or after the electrosurgical procedure. For example, the electrosurgical instrument may include a light source that may be powered by DC power to generate and emit light to illuminate an area of ​​interest, such as the target tissue and / or surgical site. As another example, the electrosurgical instrument may include a camera that may be powered by DC power to image the area of ​​interest and / or a sensor that may be powered by DC power to sense conditions related to the electrosurgery procedure (and / or the electrosurgical instrument).

[0020] One approach to providing DC power to operate the DC powered device(s) is to incorporate a battery into the handle of the electrosurgical instrument, however, this approach adds additional weight and size to the electrosurgical instrument and may make it less comfortable and / or more difficult for a user to handle.

[0021] Another approach to providing DC power to operate the DC powered device(s) is to provide a battery in a receptacle external to the electrosurgical instrument. This offers the advantage that the battery is located outside the sterile environment around the patient in the operating room. Some implementations of the external battery approach include a stand-alone battery housing with a dedicated DC power cable that is separate from the power cable that provides electrosurgical energy from the electrosurgical generator to the electrosurgical instrument. These implementations suffer from the disadvantages that the external battery pack requires additional space on the counter and the extra DC power cable poses challenges for cable management in the operating room.

[0022] Another implementation of an external battery involves incorporating the battery into a plug in the cable that couples the electrosurgical instrument to the electrosurgical generator. While this approach offers some advantages over the approaches described above, it results in a relatively bulky plug that may impede access to other features on the surface of some electrosurgical generators. In addition, for example, some electrosurgical generators may have curved surfaces and / or relatively deep sockets where the plug couples to the electrosurgical generator, features that may be incompatible with a relatively bulky plug.

[0023] The present application provides an electrosurgical instrument including a battery module that may address one or more of the problems described above. In particular, the present application provides a battery module incorporated into an electrical cable that couples the electrosurgical instrument to an electrosurgical generator. In one example, the electrical cable includes (i) a plug configured to electrically couple to the electrosurgical generator, (ii) a proximal cable including a plurality of first conductors extending from the plug to the battery module, and (iii) a distal cable including a plurality of second conductors extending from the battery module to a housing. The plurality of first conductors may include a first quantity of conductors and the plurality of second conductors includes a second quantity of conductors, the first quantity being less than the second quantity.

[0024] The battery module may further include a casing defining an interior compartment configured to receive the battery and a power driver circuit in the interior compartment of the casing. The power driver circuit may include (i) a first set of contacts electrically coupled to the plurality of first conductors, (ii) a second set of contacts electrically coupled to the plurality of second conductors, and (iii) a third set of contacts electrically coupled to the battery.

[0025] In this configuration, the plug may have a relatively smaller size than a plug that includes a battery, and as a result, the electrosurgical instrument may be compatible with more types of electrosurgical generators than some electrosurgical instruments that incorporate a battery in the plug.

[0026] 1, an electrosurgical system 100 according to one example is shown. As shown in FIG. 1, electrosurgical system 100 includes an electrosurgical generator 110 and an electrosurgical instrument 112. Generally, electrosurgical generator 110 can generate electrosurgical energy suitable for performing electrosurgery on a patient. For example, electrosurgical generator 110 can include a power converter circuit 114 that can convert grid power into electrosurgical energy, such as, for example, radio frequency (RF) output power. By way of example, power converter circuit 114 can include one or more electrical components (e.g., one or more transformers) that can control the voltage, current, and / or frequency of the electrosurgical energy.

[0027] In examples, the electrosurgical generator 110 may include a user interface 116 that may receive one or more inputs from a user and / or provide one or more outputs to a user. By way of example, the user interface 116 may include one or more buttons, one or more switches, one or more dials, one or more keypads, one or more touch screens, one or more display screens, one or more indicator lights, one or more speakers, and / or one or more tactile output devices.

[0028] In one example, the user interface 116 may be operable to select an operating mode from among a plurality of operating modes for the electrosurgical generator 110. By way of example, the operating modes may include a cutting mode, a coagulation mode, an ablation mode, and / or a sealing mode. Combinations of these waveforms may also be formed to create mixed modes. In one implementation, the operating modes may correspond to respective waveforms for the electrosurgical energy. As such, in this implementation, the electrosurgical generator 110 may generate electrosurgical energy having a waveform selected from a plurality of waveforms based at least in part on the operating mode selected using the user interface 116.

[0029] The electrosurgical generator 110 may also include one or more generator sensors 118 that may sense one or more conditions related to the electrosurgical energy and / or the target tissue. By way of example, the generator sensor(s) 118 may include one or more current sensors, one or more voltage sensors, one or more temperature sensors, and / or one or more bioimpedance sensors. In examples, the electrosurgical generator 110 may additionally or alternatively generate an amount of electrosurgical energy (e.g., power) and / or electrosurgical energy having a waveform selected from among a plurality of waveforms based on one or more parameters related to the condition(s) sensed by the generator sensor(s) 118.

[0030] In one example, the electrosurgical energy may have a frequency greater than about 100 kilohertz (kHz) to reduce (or avoid) stimulating muscles and / or nerves near the target tissue, hi another example, the electrosurgical energy may have a frequency of about 300 kHz to about 500 kHz.

[0031] 1 , electrosurgical generator 110 also includes a connector 120 that may facilitate coupling of electrosurgical generator 110 to electrosurgical instrument 112. For example, electrosurgical instrument 112 may include an electrical cable 122 having a plug 127 that may be coupled to a socket of connector 120 of electrosurgical generator 110. In this configuration, electrosurgical generator 110 may supply electrosurgical energy to electrosurgical instrument 112 via the coupling between connector 120 of electrosurgical generator 110 and electrical cable 122 of electrosurgical instrument 112. Electrical cable 122 is described in further detail below.

[0032] The electrosurgical generator 110 may further include a controller 141 that may control the operation of the electrosurgical generator 110. In examples, the controller 141 may be implemented using hardware, software, and / or firmware. For example, the controller 141 may include one or more processors and a non-transitory computer-readable medium (e.g., volatile and / or non-volatile memory) that stores machine instructions or other executable instructions. The instructions, when executed by the one or more processors, cause the electrosurgical generator 110 to perform various operations described herein. Thus, the controller 141 may receive data and store data in the memory. As shown in FIG. 1, the controller 141 may be communicatively coupled to the power converter circuit 114, the user interface 116, the generator sensor(s) 118, and / or the connector 120.

[0033] 1, electrosurgical instrument 112 may include a housing 123. Housing 123 may be an elongated structure within which and / or upon which the components of electrosurgical instrument 112 may be disposed. In some examples, housing 123 may be a one-piece monolithic structure. In other examples, housing 123 may include multiple structures coupled together.

[0034] 1 , housing 123 includes a handle 124 defining an internal bore 125, a shaft 126 extending distally from handle 124, and an electrosurgical electrode 128 extending distally from shaft 126. In general, handle 124 may be configured to facilitate a user grasping and manipulating electrosurgical instrument 112 while performing electrosurgery. For example, handle 124 may have a shape and / or size that may facilitate a user performing electrosurgery by manipulating electrosurgical instrument 112 using one hand. In one implementation, handle 124 may have a shape and / or size that facilitates a user holding electrosurgical instrument 112 in the manner one grasps a writing instrument (e.g., electrosurgical instrument 112 may be an electrosurgical pencil).

[0035] Additionally, for example, handle 124 and / or shaft 126 may be constructed from one or more materials that are electrical insulators (e.g., a plastic material), which may facilitate insulating the user from the electrosurgical energy flowing through electrosurgical instrument 112 while performing electrosurgery.

[0036] In some implementations, the shaft 126 may be coupled to the handle 124 in a fixed and non-movable manner. This may simplify and reduce manufacturing costs, for example, by simplifying electrical connections (e.g., by eliminating slip ring electrical contacts and / or sliding electrical contacts) that may otherwise be required to allow for movement of the shaft 126 and handle 124 relative to one another. In one example, the handle 124 and shaft 126 may be formed as a single monolithic structure such that the shaft 126 and handle 124 are fixed and non-movable relative to one another. In another example, the handle 124 and shaft 126 may be fixedly coupled to one another by a welded bond, an adhesive bond, and / or another bond that prevents movement between the handle 124 and shaft 126.

[0037] In other implementations, the shaft 126 may be telescopically movable relative to the handle 124. For example, the shaft 126 may be telescopically movable (e.g., movable along the longitudinal axis of the electrosurgical instrument 112) within an internal bore 125 defined by the handle 124 to extend the shaft 126 distally and retract the shaft 126 proximally relative to the handle 124. In some examples, an electrosurgical electrode 128 may be coupled to the shaft 126, such that the electrosurgical electrode 128 moves axially with the shaft 126 along the longitudinal axis relative to the handle 124. This may provide for adjusting the length of the electrosurgical instrument 112 and facilitate performing electrosurgery at different depths within tissue (e.g., due to different anatomical shapes and / or sizes of the patient) and / or at different angles.

[0038] In some implementations, electrosurgical electrode 128 may additionally or alternatively be rotatable about an axis of rotation parallel to the longitudinal axis of electrosurgical instrument 112. In some examples, electrosurgical electrode 128 may be rotatable relative to handle 124 and shaft 126. In other examples, electrosurgical electrode 128 may be rotationally fixed relative to shaft 126 such that shaft 126 and electrosurgical electrode 128 are both rotatable relative to handle 124. Rotating electrosurgical electrode 128 relative to handle 124 may facilitate adjusting the angle of electrosurgical electrode 128 relative to one or more user input devices 130 of electrosurgical instrument 112. In this configuration, a user may comfortably grip handle 124 in a position where the user's fingers may comfortably operate user input device(s) 130 while electrosurgical electrode 128 is set to a selected one of a plurality of rotational positions relative to handle 124 based, for example, on the location, size, and / or shape of a surgical site at which the user is operating.

[0039] In one implementation, the electrosurgical electrode 128 may be rotatable greater than 360 degrees relative to the handle 124. This may improve ease of use by allowing the operator to freely rotate the electrosurgical electrode 128 without restriction. However, in other implementations, the electrosurgical electrode 128 may be rotatable less than 360 degrees (e.g., rotatable 180 degrees or rotatable 360 ​​degrees). This may still allow the operator to achieve a desired rotational configuration, but with the possibility that the operator can rotate in a first direction, reach a stop that limits further rotation, and then rotate back in a second direction to achieve the desired rotational configuration.

[0040] Although it can be beneficial to provide for rotation of the electrosurgical electrode 128 relative to the handle 124 and / or shaft 126, the electrosurgical electrode 128 may, in some implementations, be rotationally fixed relative to the handle 124 and shaft 126. This can help to simplify and reduce manufacturing costs, for example, by simplifying electrical connections (e.g., by eliminating slip ring electrical contacts and / or sliding electrical contacts) that may otherwise be necessary to allow for movement of the shaft 126 and handle 124 relative to one another.

[0041] User input device(s) 130 may select between operating modes of electrosurgical instrument 112 and / or electrosurgical generator 110. For example, in one implementation, user input device(s) 130 may be configured to select between a cutting mode of operation and a coagulation mode of operation. In response to actuation of user input device(s) 130 of electrosurgical instrument 112, electrosurgical instrument 112 may (i) receive electrosurgical energy having a power level and / or waveform corresponding to the operating mode selected via user input device(s) 130, and (ii) deliver electrosurgical energy to electrosurgical electrode 128.

[0042] 1 , electrosurgical instrument 112 includes multiple electrical components that facilitate supplying electrosurgical energy that electrosurgical instrument 112 receives from electrosurgical generator 110 to electrosurgical electrodes 128. For example, electrosurgical instrument 112 may include at least one electrical component selected from a group of electrical components including an instrument printed circuit board (instrument PCB) 132 (e.g., a flexible printed circuit board), housing conductors 134, and / or shaft conductors 136, which may provide circuitry for conducting electrosurgical energy from electrical cable 122 to electrosurgical electrodes 128. One or more of these electrical components may be positioned within an internal bore 125 defined by handle 124 and / or within an inner cavity defined by shaft 126.

[0043] In an example, user input device(s) 130 may include one or more buttons on an outer surface of handle 124. Each button of user input device(s) 130 may be operable to actuate a respective one of a number of switches 138 on instrument PCB 132. Generally, switches 138 and / or instrument PCB 132 are operable to control the delivery of electrosurgical energy from electrosurgical generator 110 to electrosurgical electrodes 128. For example, in one implementation, each button may be actuated (e.g., pressed) to actuate a respective switch 138 associated with the button, causing instrument PCB 132 to send a signal to electrosurgical generator 110 to responsively deliver electrosurgical energy having a power level and / or waveform corresponding to the operational mode associated with the button. In another implementation, actuation of a button, thereby activating a respective switch 138 associated with the button, may cause the switch 138 to close and complete a circuit to the electrosurgical generator 110, causing the electrosurgical generator 110 to responsively supply electrosurgical energy having a power level and / or waveform corresponding to the operational mode associated with the button. In some examples of this implementation, the instrument PCB 132 may be omitted.

[0044] In any exemplary implementation, electrosurgical energy supplied by electrosurgical generator 110 may be supplied (i) from electrical cable 122, instrument PCB 132, and / or switch 138, and (ii) to electrosurgical electrode 128 by way of housing conductors 134 and shaft conductors 136. Thus, as shown in FIG. 1 , instrument PCB 132 may be coupled to electrical cable 122, housing conductors 134 may be coupled to instrument PCB 132 and shaft conductors 136, and shaft conductors 136 may be coupled to electrosurgical electrode 128. In this configuration, housing conductors 134 may conduct electrosurgical energy (supplied to housing conductors 134 via instrument PCB 132) to shaft conductors 136, which may conduct electrosurgical energy to electrosurgical electrode 128.

[0045] Generally, housing conductor 134 and shaft conductor 136 may each include one or more conductive elements that provide a conductive bus for supplying electrosurgical energy to electrosurgical electrode 128. More specifically, housing conductor 134 may include one or more conductive elements of handle 124 that may supply electrosurgical energy to shaft conductor 136, and shaft conductor 136 may include one or more conductive elements of shaft 126 that may supply electrical energy from housing conductor 134 to electrosurgical electrode 128. In implementations in which shaft 126 is movable or rotatable relative to handle 124, housing conductor 134 may engage shaft conductor 136 to maintain electrical coupling between housing conductor 134, shaft conductor 136, and electrosurgical electrode 128 while (i) shaft 126 and / or electrosurgical electrode 128 telescopically move relative to handle 124 and / or (ii) electrosurgical electrode 128 rotates relative to handle 124.

[0046] 1, user input device(s) 130 may be separate from electrosurgical instrument 112 in other examples. For example, user input device(s) 130 may additionally or alternatively include one or more foot pedals operable to control operation of electrosurgical instrument 112 as described above. The foot pedal(s) may be communicatively coupled to electrosurgical generator 110 to provide a signal responsive to actuation of the foot pedal(s).

[0047] As mentioned above, electrosurgical electrode 128 may apply electrosurgical energy to a target tissue to perform an electrosurgery procedure (e.g., cutting, coagulating, ablating, and / or sealing the target tissue). In an example, electrosurgical electrode 128 may include an electrosurgical substrate formed from an electrically conductive material. As an example, the electrically conductive material may be stainless steel.

[0048] The electrosurgical substrate may extend axially from the proximal end of the electrosurgical electrode 128 to the distal end of the electrosurgical electrode 128. The proximal end of the electrosurgical electrode 128 may receive electrosurgical energy from the electrosurgical instrument 112 (e.g., via the housing conductor 134 and the shaft conductor 136 as described above), and the distal working portion of the electrosurgical electrode 128 may apply the electrosurgical energy to the target tissue. In one implementation, the electrosurgical substrate may include a shank portion that extends from the proximal end of the electrosurgical electrode 128 to the distal working portion of the electrosurgical electrode 128. The distal working portion may be configured to use the electrosurgical energy to at least one of cut or coagulate tissue in monopolar electrosurgery.

[0049] In some examples, the distal working portion may define an electrosurgical blade. For example, the electrosurgical blade may include (i) a first lateral surface, (ii) a second lateral surface opposite the first lateral surface, (iii) a first major surface extending between the first and second lateral surfaces on a first side of the electrosurgical blade, and (iv) a second major surface extending between the first and second lateral surfaces on a second side of the electrosurgical blade opposite the first side. The first and second lateral surfaces have a surface area that is relatively small compared to the surface areas of the first and second major surfaces such that the thickness (e.g., the dimension between the first and second major surfaces) of the electrosurgical blade is relatively small compared to the length (e.g., the dimension spanning between the proximal and distal ends of the electrosurgical electrode 128) and width (e.g., the dimension between the first and second lateral surfaces).

[0050] In some instances, the distal working portion of electrosurgical electrode 128 may also include an outer layer of material covering at least a portion (or all) of the electrosurgical substrate. For example, the outer layer of material may be formed from at least one material selected from the group consisting of polymeric materials, fluorocarbon materials (e.g., polytetrafluoroethylene (PTFE)), silicone, enamel, ceramic materials, and inorganic lubricous materials (e.g., titanium nitride, zirconium nitride, titanium aluminum nitride, and nitrone). The outer layer of material may, for example, help inhibit eschar buildup and / or focus the electrosurgical energy on one or more portions of electrosurgical electrode 128.

[0051] In some examples, the distal working portion of electrosurgical electrode 128 may additionally include an intermediate layer between the electrosurgical substrate and the outer layer. The intermediate layer may be configured to provide thermal conductivity to help mitigate heating of the outer layer that leads to destruction of the outer layer. The intermediate layer may also be configured to maintain the electrical conductivity of the electrosurgical substrate such that the intermediate layer does not degrade the transmission of electrosurgical energy from the electrosurgical substrate to the target tissue.

[0052] The intermediate layer may be an anisotropic thermally conductive material, in which the in-plane (e.g., parallel to the electrode surface) thermal conductivity significantly exceeds the out-of-plane (e.g., perpendicular to the electrode surface) thermal conductivity. The anisotropic thermally conductive material has a coefficient of thermal expansion that is matched (or about 10% greater or about 10% less) than the electrosurgical substrate and outer layer. By way of example, the intermediate layer may comprise at least one material selected from the group consisting of pyrolytic graphite / carbon, graphene, and molybdenum disulfide.

[0053] In examples, the electrosurgical instrument 112 may additionally or alternatively include features for venting surgical smoke from the distal end of the shaft 126 and / or the electrosurgical electrode 128 to a location outside the surgical site. Surgical smoke is a by-product of various surgical procedures. For example, during a surgical procedure, surgical smoke may be generated as a by-product of an electrosurgical unit (ESU), a laser, an electrocautery device, an ultrasonic device, and / or other powered surgical instruments (e.g., bone saws and / or drills). In some examples, surgical smoke may include toxic gases and / or biological products resulting from the destruction of tissue. In addition, surgical smoke may include an unpleasant odor. For these and other reasons, many guidelines indicate that exposure of surgical personnel to surgical smoke should be reduced or minimized.

[0054] To reduce (or minimize) exposure to surgical smoke, a smoke evacuation system can be used during a surgical procedure. Generally, a smoke evacuation system can include a suction pump 145 that can generate sufficient suction and / or vacuum pressure to draw the surgical smoke away from the surgical site. In some implementations, the smoke evacuation system can be coupled to an exhaust system (e.g., an in-wall exhaust system) that exhausts the surgical smoke from the operating room. In other implementations, the smoke evacuation system can filter the air containing the surgical smoke and return the air to the operating room. In examples, the suction pump 145 and the electrosurgical generator 110 can be provided as separate devices or can be integrated into a single device (e.g., in a common housing).

[0055] 1, shaft 126 may include a smoke evacuation channel 148 within an inner cavity of shaft 126. Smoke evacuation channel 148 may also include a smoke inlet that may extend circumferentially about a central axis of a distal portion of electrosurgical electrode 128. In this configuration, the smoke inlet of the smoke evacuation channel may serve to receive surgical smoke into smoke evacuation channel 148 at all rotational alignments of electrosurgical electrode 128 relative to handle 124 and / or electrosurgical instrument 112 relative to target tissue. However, in other examples, smoke evacuation channel 148 may include one or more smoke inlets that do not extend circumferentially around electrosurgical electrode 128.

[0056] In one example, the smoke evacuation channel 148 of the shaft 126 defines a first portion of the smoke flow path, and the internal bore 125 of the handle 124 defines a second portion of the smoke flow path. In this configuration, surgical smoke may be received from the surgical site into the smoke evacuation channel 148 of the shaft 126 and flow proximally along the smoke evacuation channel 148 to the internal bore 125 of the handle 124. In the internal bore 125 of the handle 124, the smoke may further flow to a smoke conduit 150 coupled to a proximal end of the handle 124 and configured to convey the smoke from the handle 124 to the suction pump 145.

[0057] 1, the electrosurgical instrument 112 includes at least one direct current (DC) device 140 and a battery module 142. Generally, the DC device 140 is configured to use DC power provided by the battery module 142 to perform functions associated with the electrosurgical system 100. The DC device 140 may be disposed at least partially or entirely within the housing 123 and / or at least partially or entirely on an exterior surface of the housing 123. By way of example, the DC device 140 may include at least one device selected from the group consisting of one or more DC power-receiving sensors, one or more cameras, one or more ultrasound transmitters, one or more light sources 144, one or more tactile devices, and one or more fluid pumps.

[0058] In examples including a DC power-receiving sensor, the DC power-receiving sensor may sense one or more operating conditions during the electrosurgical procedure. For example, the DC power-receiving sensor(s) may include at least one sensor selected from the group consisting of: (i) a temperature sensor, (ii) an electrochemical sensor, (iii) a force sensor, (iv) a mass load sensor, (v) a dielectric sensor, (vi) a conductivity sensor, (vii) a metal detection sensor, (viii) a tracking sensor configured to sense at least one of a location of the electrosurgical electrode and an orientation of the electrosurgical electrode, (ix) an optical sensor, and (x) a smoke detection sensor. In examples, the DC power-receiving sensor(s) transmit a sensor signal to controller 141 of electrosurgical generator 110 to provide a basis for feedback control of electrosurgical system 100 to improve the electrosurgical procedure.

[0059] In examples including a camera, the camera may capture images of the area of ​​interest using DC power provided by battery module 142. For example, the camera may be configured with a distally directed field of view to capture images of the electrosurgical electrode 128, the target tissue, and / or the surgical site. This may help the user visualize cutting and / or coagulating the target tissue, among other things.

[0060] In examples including an ultrasonic transmitter, the ultrasonic transmitter may be used to detect proximity to a conductive object (e.g., one or more pacemaker leads) within the patient. In one example, the ultrasonic transmitter may be configured to send a sensor signal to a controller (e.g., controller 141 or instrument PCB 132) in response to detecting limited proximity to the conductive object, causing the controller to terminate and / or prevent delivery of electrosurgical energy to electrosurgical electrode 128. This may help improve safe operation of electrosurgical system 100.

[0061] In examples including light source(s) 144, the light source(s) 144 may generate light that may be emitted by the electrosurgical instrument 112 to illuminate an area of ​​interest (e.g., target tissue at a surgical site). In some implementations, the light source(s) 144 may be located at the distal end of the housing 123 and / or at the distal end of the shaft 126 to provide light directly in a distal direction to illuminate the surgical distal end of the electrosurgical electrode 128.

[0062] 1, the light source(s) 144 may be optically coupled to an optical structure 146 that is configured to receive light emitted by the light source(s) 144 and transmit the light distally towards the surgical site to illuminate the surgical site while performing electrosurgery using the electrosurgical electrodes 128. Configuring the light source(s) 144 to directly illuminate the surgical field may help to reduce costs of manufacture, for example, while transmitting light using the optical structure 146 may help to improve the quality of light transmitted from the electrosurgical instrument 112 (e.g., by providing light with improved uniformity and / or with reduced heat generation).

[0063] By way of example, in implementations that include an optical structure 146, the optical structure 146 may include at least one optical structure selected from the group consisting of an optical lens, a non-fiber optic light guide, and an optical fiber. When the optical structure 146 includes an optical lens (e.g., a parabolic lens, an aspheric lens, and / or a Fresnel lens), the optical structure 146 may help direct the light emitted by the light source 144 in a distal direction, thereby improving the quality of the light illuminating the surgical site. The optical structure 146 may additionally or alternatively include a non-fiber optic light guide and / or an optical fiber to transmit light over a relatively large distance in the shaft 126. For example, the light guide may transmit light in a distal direction via total internal reflection. In such implementations, the light guide may include cladding and / or voids on an outer surface of the light guide to help promote total internal reflection. In some implementations, the non-fiber optic light guide may be formed as a single monolithic structure.

[0064] In some examples, the optical structure 146 may additionally or alternatively include other light shaping optical elements, such as, for example, multiple facets, one or more prisms, and / or one or more optical gratings. While the optical structure 146 may serve to improve the quality of light directed to the surgical site, in other examples, the electrosurgical instrument 112 may omit the optical structure 146 and instead emit light from the light source 144 directly onto the surgical field without transmitting light through the optical structure 146.

[0065] In FIG. 1 , the light source 144 may be coupled to the shaft 126. As such, the light source 144 may also telescopically move with the shaft 126 relative to the handle 124. However, in other examples, the light source 144 may be in an internal bore of the handle 124 and / or coupled to an outer surface of the handle 124. By way of example, the light source 144 may include one or more light emitting diodes (LEDs), organic light emitting diodes (OLEDs), optical fibers, non-fiber optic waveguides, and / or lenses. Additionally, for example, the light source 144 may include a light emitting diode printed circuit board (LED PCB) having one or more light sources (e.g., LEDs). As described in more detail below, the LED PCB may include a PCB opening through which one or more other components of the electrosurgical instrument 112 (e.g., electrosurgical electrodes 128) may extend.

[0066] Optical structure 146 may be at the distal end of shaft 126. In some examples, optical structure 146 may circumferentially surround electrosurgical electrode 128 to emit light distally around all sides of electrosurgical electrode 128. This may help to reduce shadows and provide greater uniformity of illumination at all rotational alignments of shaft 126 relative to housing 123 and / or electrosurgical instrument 112 relative to the target tissue. However, in other examples, optical structure 146 may extend partially, but not entirely, around electrosurgical electrode 128.

[0067] In examples, user input device(s) 130, instrument PCB 132, switch 138, housing conductors 134, shaft conductors 136, electrical cable 122, and / or battery module 142 may provide DC power from battery module 142 to DC device 140. Electrical cable 122 and battery module 142 are described in further detail below with respect to Figures 4A-4F.

[0068] The user input device(s) 130 may be actuated to operate the DC device(s) 140 (e.g., cause the light source(s) 144 to generate light). In one example, the user input device(s) 130 may include a button that independently controls the DC device(s) 140, separate from the button(s) that control the electrosurgical mode of operation of the electrosurgical instrument 112. In another example, the user input device(s) 130 and the instrument PCB 132 may be configured such that operation of the button(s) that control the electrosurgical mode of operation simultaneously controls operation of the DC device 140 (e.g., the light source 144 may be automatically actuated to emit light when the button is actuated to apply electrosurgical energy to the electrosurgical electrode 128).

[0069] 1 , in response to manipulation of user input device(s) 130 to activate DC device(s) 140, the battery module 142 may provide power (e.g., a DC voltage) to the DC device(s) 140 via the electrical cable 122, the instrument PCB 132, the housing conductors 134, and / or the shaft conductors 136. In this implementation, one or more of the conductive elements of the housing conductors 134 may be configured to provide power from the battery module 142 to the DC device(s) 140 and / or to return power from the DC device(s) 140 to the battery module 142. Thus, the housing conductors 134 may additionally or alternatively help provide electrical communication between the battery module 142 and the DC device(s) 140 as the shaft 126 and light source 144 telescopically move and / or rotate relative to the handle 124.

[0070] In the examples described above, the user input device(s) 130 on the handle 124 may be manipulated to control the operation of the DC device(s) 140, however, the DC device(s) 140 may additionally or alternatively be operated by one or more user input device(s) on the electrosurgical generator 110 (e.g., via the user interface 116) and / or on the plug 127 of the electrical cable 122.

[0071] 2, a perspective view of another implementation of an electrosurgical instrument 112 is shown according to one example. In particular, FIG. 2 shows an implementation of an electrosurgical instrument 112 that (i) includes an illumination feature, and (ii) has a shaft 126 that is axially movable and rotatable relative to a handle 124. As shown in FIG. 2, the electrosurgical instrument 112 includes a housing 123 that defines an internal bore 125, a shaft 126 that is telescopically movable within the internal bore 125 of the housing 123, and an electrosurgical electrode 128 coupled to the shaft 126. However, as described above, the shaft 126 may in other examples be fixedly coupled to the handle 124 such that the shaft 126 is not movable relative to the handle 124.

[0072] Additionally, in FIG. 2, optical structure 146 is at distal end 252 of shaft 126. In this configuration, optical structure 146 may telescope with shaft 126 relative to housing 123. In FIG. 2, optical structure 146 extends around electrosurgical electrode 128. This may help emit light in a relatively uniform manner by reducing (or preventing) shadows due to the orientation of optical structure 146 and electrosurgical electrode 128 relative to the surgical site. However, in other examples, optical structure 146 may not extend all the way around electrosurgical electrode 128 at distal end 252 of shaft 126 and / or optical structure 146 may be at a different location on shaft 126 and / or housing 123. In still other examples, electrosurgical instrument 112 may omit optical structure 146 and instead, light source 144 may be disposed on an outer surface of housing 123 such that light source 144 may directly illuminate the area of ​​interest.

[0073] In some examples, the electrosurgical instrument 112 may include a collar 254 at the proximal end of the housing 123. The collar 254 may be rotatable relative to the housing 123 to increase and / or decrease friction between an outer surface of the shaft 126 and an inner surface of the collar 254. In this manner, the collar 254 allows and / or inhibits axial telescopic movement of the shaft 126 relative to the housing 123.

[0074] 2, user input device(s) 130 include a first button 230A, a second button 230B, and a third button 230C on an exterior surface of housing 123. In one implementation, first button 230A may be actuated to operate electrosurgical instrument 112 in a cutting mode of operation, second button 230B may be actuated to operate electrosurgical instrument 112 in a coagulation mode of operation, and third button 230C may be actuated to operate light source 144 (i.e., to cause light source 144 to emit light or to stop emitting light). As described above, user input device(s) 130 may be configured differently in other examples. For example, electrosurgical instrument 112 may be operable in a fewer number of operating modes, a greater number of operating modes, and / or different types of operating modes in other examples (such as the exemplary operating modes described above). Additionally, for example, the at least one user input device 130 may additionally or alternatively include a user interface 116 of the electrosurgical generator 110 and / or another external device (e.g., a foot switch) for operating the electrosurgical instrument 112 in one or more operating modes.

[0075] 2, electrosurgical instrument 112 includes an electrical cable 122. At a proximal end 256 of electrical cable 122, electrical cable 122 includes a plug 127 configured to couple to connector 120 of electrosurgical generator 110. A distal end of electrical cable 122 is coupled to instrument PCB 132 in an internal cavity of housing 123 (e.g., in internal bore 125). In this configuration, electrical cable 122 extends proximally from housing 123 to plug 127 (e.g., from a proximal end of housing 123 to plug 127).

[0076] 2, the electrical cable 122 includes a battery module 142 between a proximal end 256 of the electrical cable 122 and a distal end of the electrical cable 122. In this configuration, the electrical cable 122 includes a proximal cable 258 that extends from the plug to the battery module 142 and a distal cable 260 that extends from the battery module 142 to the housing 123. By positioning the battery module 142 between the proximal cable 258 and the distal cable 260, the electrosurgical instrument 112 may have a reduced size as compared to an electrosurgical instrument that incorporates a battery in the handle 124. Additionally, positioning the battery module 142 between the proximal cable 258 and the distal cable 260 may reduce the size and bulk of the plug 127 as compared to an electrosurgical instrument 112 that incorporates a battery in the plug 127 and improve access to the area(s) near the connector 120 on the electrosurgical generator 110. Additionally, positioning the battery module 142 between the proximal cable 258 and the distal cable 260 may improve the ease of replacing the battery as compared to electrosurgical instruments that have the battery integrated into the housing 123 or plug 127.

[0077] In some examples, the proximal cable 258 has a first length and the distal cable 260 has a second length, the second length being greater than the first length. This can be useful for positioning the battery module 142 closer to the electrosurgical generator 110 than the handle 124, and therefore further from the sterile environment (e.g., at the surgical site). By way of example, the first length can be from about 10 cm to about 2 meters in length, and / or the second length can be from about 2 meters to about 5 meters in length.

[0078] In other examples, the second length may be smaller than the first length. This may be beneficial in implementations in which the battery module 142 includes a user output device (e.g., a display and / or indicator light) that provides information to a user during a procedure. For example, when the second length is smaller than the first length, the battery module 142 may be closer to the operator, which may facilitate receiving information from the user output device (e.g., compared to an alternative implementation in which the second length is larger than the first length and the battery module 142 is farther from the operator).

[0079] 3, a simplified block diagram of an electrical cable 122 is shown, according to one example. As shown in FIG. 3, the electrical cable 122 includes a plug 127 configured to electrically couple to the electrosurgical generator 110, a proximal cable 258 including a plurality of first conductors 362 extending from the plug 127 to the battery module 142, and a distal cable 260 including a plurality of second conductors 364 extending from the battery module 142 to the housing 123. In general, the first conductors 362 of the proximal cable 258 can supply electrosurgical energy from the electrosurgical generator 110 to the battery module 142, and the second conductors 364 can both (i) supply electrosurgical energy towards the electrosurgical electrode 128 and (ii) supply DC power to the DC device 140 from the battery module 142.

[0080] For example, first conductors 362 may include a first quantity of conductors and second conductors 364 include a second quantity of conductors, the first quantity being less than the second quantity. In this configuration, first conductors 362 and a first subset of second conductors 364 are configured to supply electrosurgical energy from electrosurgical generator 110 towards electrosurgical electrodes 128, and a second subset of second conductors 364 are configured to supply power from batteries 366 of battery module 142 to DC device 140.

[0081] In one implementation, the first quantity of conductors is three and the second quantity of conductors is five. In this implementation, the first subset of second conductors 364 includes three conductors for electrosurgical energy and the second subset of second conductors 364 includes two conductors for DC power. In one example, the first subset of three conductors 364 may include cutting conductors for signaling the electrosurgical generator 110 to provide electrosurgical energy for a cutting operation, coagulation conductors for signaling the electrosurgical generator 110 to provide electrosurgical energy for a coagulation operation, and power transmission conductors for supplying electrosurgical energy from the electrosurgical generator 110 to the electrosurgical electrodes 128. However, in other examples, the first conductors 362 and the second conductors 364 may include different quantities of conductors. For example, the second quantity of second conductors 364 may be equal to X+2Y, where X is the first quantity of first conductors 362 and Y is the quantity of DC devices 140. As an example, in an implementation with three first conductors 362 and two DC devices 140, the second quantity of conductors may be seven.

[0082] 3, the battery module 142 includes a casing 368. The casing 368 defines an interior compartment configured to receive the battery 366. In some examples, the battery 366 may include a single battery. In other examples, the battery 366 may include multiple batteries. In some implementations, the casing 368 may completely surround the battery 366. This may help to mitigate foreign objects (e.g., liquids) from contacting the battery 366 and affecting the operation of the battery 366. In other implementations, the casing 368 may hold the battery 366 without completely surrounding the battery 366.

[0083] In some examples, the battery 366 may be insertable and removable from the casing 368 (e.g., to facilitate inserting the battery 366 prior to initial use of the electrosurgical instrument 112 and / or to replace an expired battery with a new battery). In such examples, the casing 368 may be actuated between (i) a closed state in which the casing 368 inhibits or prevents access to the battery 366 in the internal compartment, and (ii) an open state in which the casing 368 allows access to the battery 366 in the internal compartment. In other examples, the battery 366 may not be replaceable, and the casing 368 may be configured only to inhibit access to the battery 366 in the internal compartment. For example, the casing 368 may be configured such that the casing can be actuated from an open state to a closed state (e.g., during the manufacturing process and / or prior to initial use of the electrosurgical instrument 112) but cannot be returned from the closed state to the open state.

[0084] The battery module 142 may also include a power driver circuit 370 in an internal compartment of the casing 368. The power driver circuit 370 may include (i) a first set of contacts 372 electrically coupled to the first conductors 362, (ii) a second set of contacts 374 electrically coupled to the second conductors 364, and (iii) a third set of contacts 376 electrically coupled to the battery 366. The power driver circuit 370 may include one or more electrical components that may operate to control one or more functions related to providing electrosurgical energy from the electrosurgical generator 110 to the electrosurgical electrodes 128 (and / or the instrument PCB 132) and / or providing DC power from the battery 366 to the DC device 140. For example, the power driver circuit 370 may include one or more electrical components that may provide reverse polarity protection, surge protection, electromagnetic interference (EMI) protection, overcharge protection, overdischarge protection, and / or over-drain protection in association with the battery 366. The power driver circuit 370 may additionally or alternatively provide a battery management system that may monitor the status of the battery 366 (e.g., the voltage, temperature, state of charge (SOC), depth of discharge (DOD), state of health (SOH), and / or current of the battery 366).

[0085] More generally, the power driver circuit 370 may be configured to provide (i) transmission of electrosurgical energy from the first conductors 362 of the proximal cable 258 to a first subset of the second conductors 364 of the distal cable 260, and (ii) transmission of DC power between the battery 366 and the second subset of the second conductors 364.

[0086] In one example, power driver circuit 370 may include a power printed circuit board (PCB) 378 electrically coupled to first set of contacts 372, second set of contacts 374, and / or third set of contacts 376. Power PCB 378 may include electrical components for performing the power related operations described above in connection with battery 366 and / or for providing electrosurgical energy from proximal cable 258 to distal cable 260. In one example, first set of contacts 372 may be at a proximal end of power PCB 378, second set of contacts 374 may be at a distal end of power PCB 378, and third set of contacts 376 may be positioned between the proximal end of power PCB 378 and the distal end of power PCB 378.

[0087] 2 and 3, plug 127 may include a plurality of prongs 280 configured to be received in respective sockets of connector 120 of electrosurgical generator 110. Prongs 280 may be provided in a quantity corresponding to the quantity of first conductors 362 of proximal cable 258. In this configuration, each prong 280 may be electrically coupled to a respective one of the first conductors 362 and may provide for electrically coupling each one of the first conductors 362 to a respective one of the sockets of connector 120. In the example shown in FIG. 2, plug 127 has three prongs 280 configured to couple to electrosurgical generator 110. Thus, in the example of FIG. 2, proximal cable 258 may include three first conductors 362 and first contacts 372 may include three contacts. 2, distal cable 260 may include five second contacts 374 and five second conductors 364 (e.g., including three second conductors 364 for electrosurgical energy and two second conductors 364 for DC power). As discussed above, other examples may include different quantities of prongs 280, first conductors 362, first contacts 372, second contacts 374, and / or second conductors 364.

[0088] 4A-4F, an implementation of a battery module 142 according to one example is shown. In particular, FIG. 4A shows a perspective view of the battery module 142 according to this example in an open state, FIG. 4B shows a first side view of the battery module 142 in a closed state, FIG. 4C shows a second side view of the battery module 142 in a closed state, FIG. 4D shows a side view of the battery module 142 in an open state, FIG. 4E shows a perspective view of the power driver circuit 370 shown in FIG. 4A, and FIG. 4F shows a bottom view of the power driver circuit 370 shown in FIG. 4E.

[0089] 4A, the battery module 142 includes a casing 368 that defines an interior compartment 482 configured to receive a battery 366. In the example shown in FIGS. 4A-4H, the casing 368 is configured to receive a single battery 366. However, as described above, in other examples, the battery 366 may include multiple batteries.

[0090] As described above, the battery module 142 may also include a power driver circuit 370 in the interior compartment 482 of the casing 368. As shown in Figures 4E and 4F, the power driver circuit 370 may include (i) a first set of contacts 372 electrically coupled to the first conductor 362, (ii) a second set of contacts 374 electrically coupled to the second conductor 364, and (iii) a third set of contacts 376 electrically coupled to the battery 366. Additionally, as shown in Figures 4E and 4F, the power driver circuit 370 may include a power printed circuit board (PCB) 378 electrically coupled to the first set of contacts 372, the second set of contacts 374, and / or the third set of contacts 376.

[0091] In this example, the first set of contacts 372 may be at a proximal end 478A of the power PCB 378, the second set of contacts 374 may be at a distal end 478B of the power PCB 378, and the third set of contacts 376 may be positioned between the proximal end 478A of the power PCB 378 and the distal end 478B of the power PCB 378. This may help to reduce the length of each of the proximal and distal cables 258 and 260 and / or may help improve safety by locating the relatively high energy connections of the first and second sets of contacts 372 and 374 away from the third set of contacts 376 with which a user may interact while replacing the battery 366.

[0092] 4A and 4E, the battery module 142 may include one or more battery retaining clips 484 positioned between each of the third set of contacts 376. In this configuration, the battery retaining clip(s) 484 may help maintain the battery 366 in a position in which the battery 366 is in electrical contact with the third set of contacts 376. Additionally, the one or more battery retaining clips 484 may help inhibit the battery 366 from inadvertently falling out of the battery module 142 when the casing 368 is in the open configuration. While the one or more battery retaining clips 484 may provide certain advantages, in other examples, the battery module 142 may omit the battery retaining clip(s) 484.

[0093] As described above, in some examples, the battery 366 may not be replaceable and the casing 368 may only have a closed state that inhibits access to the battery 366 in the interior compartment 482. However, in the implementation shown in Figures 4A-4H, the casing 368 may be actuated between (i) a closed state in which the casing 368 inhibits or prevents access to the battery 366 in the interior compartment 482, and (ii) an open state in which the casing 368 allows access to the battery 366 in the interior compartment 482 (e.g., the casing 368 may be opened and closed multiple times to facilitate insertion, removal, and / or replacement of the battery 366).

[0094] 4A-4H, for example, the casing 368 includes multiple sections 468A-468C hinged to one another to facilitate actuation of the casing 368 between an open state and a closed state. The sections 468A-468C are configured to move between an open state (shown in FIGS. 4A and 4D) that provides access to the interior compartment 482 of the casing 368 and a closed state (shown in FIGS. 4B and 4C) that blocks access to the interior compartment 482 of the casing 368.

[0095] Sections 468A-468C may include a bottom section 468A coupled to power driver circuit 370 and a top section 468B hinged to bottom section 468A. When casing 368 is in a closed state, bottom section 468A and top section 468B may define an interior compartment 482. To secure casing 368 in a closed state, casing 368 may include a locking mechanism 486. As an example, in FIGS. 4A-4H, locking mechanism 486 includes a latch 486A (shown in FIGS. 4A and 4C) on top section 468B that may engage with a detent 486B (shown in FIG. 4B) on bottom section 468A to releasably hold casing in a closed state. In other examples, the locking mechanism 486 may additionally or alternatively include at least one of the group consisting of a sliding latch, a threaded connection, a mechanical fastener (e.g., a screw), a spring latch, and a lock and key mechanism.

[0096] 4A and 4D, sections 468A-468C of casing 368 may also include a middle section 468C hinged to bottom section 468A. In this example, casing 368 may transition from an open state to a closed state by first folding middle section 468C over bottom section 468A and then folding top section 468B over both bottom section 468A and middle section 468C. After top section 468B is folded over both bottom section 468A and middle section 468C, bottom section 468A and top section 468B may be secured together by locking mechanism 486.

[0097] 4A and 4D, the middle section 468C may include a cradle portion 488 that may be configured to receive the battery 366 when the battery 366 is coupled to the third contacts 376 and / or the battery retaining clip 484. For example, the cradle portion 488 may have a concave shape that generally corresponds to an outer surface contour of the battery 366. This may further help hold the battery 366 in a position where the battery 366 is in electrical contact with the third set of contacts 376.

[0098] As shown in FIG. 4A, the middle section 468C may include a number of openings 490, each aligned with a respective one of the battery retaining clips 484 and / or the third contacts 376. This may allow the battery retaining clips 484 and / or the third contacts 376 to extend through the openings 490 when the middle section 468C is positioned over the bottom section 468A. In addition, the top section 468B may include one or more ribs 392 to help hold the battery 366 in a position where the battery makes electrical contact with the third set of contacts 376. Thus, in the configuration shown in FIG. 4A, the battery 366 may be securely held in a position where the battery makes electrical contact with the third set of contacts 376 by (i) the battery retaining clips 484, (ii) the cradle portion 488 of the middle section 468C, and (iii) the ribs 492 of the top section 468B.

[0099] 4A-4H, the proximal cable 258 and the distal cable 260 are each coupled to a power driver circuit 370. One challenge associated with this configuration of the electrical cable 122, where the proximal cable 258 is not integral or monolithic with the distal cable 260, is reducing inadvertent disconnection between the power driver circuit 370 and the proximal cable 258 and / or reducing inadvertent disconnection between the power driver circuit 370 and the distal cable 260. In an example, the battery module 142 may include one or more features that may assist in coupling the proximal cable 258 and / or the distal cable 260 to the casing 368 and / or the power driver circuit 370, thereby addressing such inadvertent disconnection challenges.

[0100] For example, the battery module 142 may include a first clamp 494 at a proximal end of the casing 368 configured to apply a clamping force to the proximal cable 258 and a second clamp 496 at a distal end of the casing 368 configured to apply a clamping force to the distal cable 260. The clamping force may help to reduce forces pulling the proximal cable 258 and / or the distal cable 260 away from the power driver circuit 370 and / or the casing 368.

[0101] 4A and 4G, the first clamp 494 may include a first recess 494A in the bottom section 468A and a first recess 494B in the top section 468B, and the second clamp 496 may include a second recess 496A in the bottom section 468A and a second recess 496B in the top section 468B. The first clamp 494 may also include a first recess 494C in the middle section 468C, and the second clamp 496 may further include a second recess 496C in the middle section 468C. As mentioned above, the middle section 468C is positioned between the top section 468B and the bottom section 468A when the multiple sections 468A-468C are in a closed state. The first clamp 494 may be defined by the first recess 494A, the first recess 494B, or the first recess 494C in Fig. 4A, but in another example, the first clamp 494 may be defined by two features selected from the group consisting of the first recess 494A, the first recess 494B, and the first recess 494C. Similarly, the second clamp 496 may be defined by the first recess 494A, the first recess 494B, or the first recess 494C in Fig. 4A, but in another example, the second clamp 496 may be defined by two features selected from the group consisting of the second recess 496A, the second recess 496B, or the second recess 496C.

[0102] In this configuration, the first clamp 494 may have a circumference less than the circumference of the proximal cable 258 to apply a clamping force to the proximal cable 258 when the casing 368 is in the closed state. Similarly, the second clamp 496 may have a circumference less than the circumference of the distal cable 260 to apply a clamping force to the distal cable 260 when the casing 368 is in the closed state.

[0103] In some examples, the battery module 142 may additionally or alternatively include a first strain relief structure 497 to assist in reducing strain on the proximal cable 258 and / or a second strain relief structure 498 to assist in reducing strain on the distal cable 260. By way of example, in FIG. 4A , the casing 368 includes a first strain relief structure 497 at a location in the interior compartment 482 between the first clamp 494 and the power driver circuit 370, and a second strain relief structure 498 at a location in the interior compartment 482 between the power driver circuit 370 and the second clamp 496. In this example, the first strain relief structure 497 may include a first receptacle configured to receive the proximal cable 258, and the second strain relief structure 498 may include a second receptacle configured to receive the distal cable 260. The casing 368 has a length that extends in a dimension between a proximal end of the casing 368 and a distal end of the casing 368. In the dimension perpendicular to the length, at least one of (i) the first strain relief structure 497 is offset from the first clamp 494 and the first set of contacts 372 of the power driver circuit 370, or (ii) the second strain relief structure 498 is offset from the second clamp 496 and the second set of contacts 374 of the power driver circuit 370. Offsetting the first strain relief structure 497 and / or the second strain relief structure 498 may cause the proximal cable 258 and / or the distal cable 260 to have a serpentine configuration that reduces strain on the proximal cable 258 and / or the distal cable 260, respectively.

[0104]

[0046] Referring now to Figure 5, another example battery module 142 is shown. The battery module 142 shown in Figure 5 is substantially similar or identical to the battery module 142 shown in Figures 1-4F, except that the battery module 142 shown in Figure 5 includes a locking mechanism 586 that is different from the locking mechanism 468 of the battery module 142 shown in Figures 4A-4D.

[0105] 5, the battery module 142 includes a locking mechanism 586 configured to be actuated between a locked state and an unlocked state by a portion of the plug 127. In the locked state, the locking mechanism 586 inhibits or prevents the battery module 142 from being actuated from a closed state to an open state. In the unlocked state, the locking mechanism 586 allows the battery module 142 to be actuated from a closed state to an open state. The locking mechanism 586 helps to mitigate inadvertent opening of the casing 368 of the battery module 142.

[0106] In the example shown in FIG. 5, the locking mechanism 586 includes a keyhole 599 on the casing 368, which is configured to receive at least one of the protrusions 280 of the plug 127 (e.g., the three protrusions 280 of the plug 127 in the example shown in FIG. 5). In this configuration, the protrusion(s) 280 of the plug 127 may be inserted into the keyhole 599 to actuate the locking mechanism 586 from a locked state to an unlocked state. Configuring the locking mechanism 586 to be actuated by a portion of the plug 127 (e.g., one or more of the protrusions 280) may alleviate the need for a separate key, thus ensuring that the mechanism for opening the battery module 142 is always in the same location as the battery module 142. However, in other examples, the locking mechanism 586 may additionally or alternatively include a separate key for actuating the locking mechanism 586.

[0107] In some examples, the locking mechanism 586 may be configured to automatically actuate from an unlocked state to a locked state in response to actuating the battery module 142 from an open state to a closed state (e.g., without the use of a key). This may simplify operation of the locking mechanism 586. In other examples, the locking mechanism 586 may be configured such that a portion of the plug 127 and / or a separate key used to actuate the locking mechanism 586 from a closed state to an open state is also used to actuate the locking mechanism 586 from an open state to a closed state.

[0108] Referring now to FIG. 6, a simplified block diagram of an electrical cable 122 for the electrosurgical system 100 of FIG. 1 is shown, according to another example. As shown in FIG. 6, the electrical cable 122 includes a plug 127 configured to electrically couple to the electrosurgical generator 110, a proximal cable 258 extending from the plug 127 to the battery module 142, and a distal cable 260 extending from the battery module 142 to the housing 123. The battery module 142 includes a casing 668. The casing 368 defines an interior compartment configured to receive a battery 366. In some examples, the battery 366 may include a single battery. In other examples, the battery 366 may include multiple batteries. In some implementations, the casing 668 may completely surround the battery 366. This may help to mitigate foreign objects (e.g., liquids) from contacting the battery 366 and affecting the operation of the battery 366. In other implementations, the casing 668 may hold the battery 366 without completely enclosing the battery 366 .

[0109] In some examples, the battery 366 may be insertable and removable from the casing 368 (e.g., to facilitate inserting the battery 366 prior to initial use of the electrosurgical instrument 112 and / or to replace an expired battery with a new battery). In such examples, the casing 668 may be actuated between (i) a closed state in which the casing 668 inhibits or prevents access to the battery 366 in the internal compartment, and (ii) an open state in which the casing 668 allows access to the battery 366 in the internal compartment. In other examples, the battery 366 may not be replaceable, and the casing 668 may be configured only to inhibit access to the battery 366 in the internal compartment.

[0110] The battery module 142 may also include a battery PCB 678 in an internal compartment of the casing 668. The battery PCB 678 may include a plurality of first contacts 672 that electrically couple the battery 366 to the battery PCB 678. In some examples, the battery PCB 678 may include electrical components for performing the power-related operations described above in connection with the battery 366 (e.g., providing DC power from the battery 366 to the DC device 140). For example, the battery PCB 678 may include one or more electrical components that may provide reverse polarity protection, surge protection, electromagnetic interference (EMI) protection, overcharge protection, overdischarge protection, and / or overdrain protection in connection with the battery 366. The battery PCB 678 may additionally or alternatively provide a battery management system that may monitor a status of the battery 366 (e.g., a voltage, temperature, state of charge (SOC), depth of discharge (DOD), state of health (SOH), and / or current of the battery 366).

[0111] 6, the electrical cable 122 includes a number of electrosurgical energy (ES energy) conductors 662 that extend the entire length of the electrical cable 122 between the plug 127 and the housing 123. The ES energy conductors 662 may deliver electrosurgical energy from the electrosurgical generator 110 to the electrosurgical electrodes 128 (e.g., via the instrument PCB 132, the housing conductor(s) 134, the shaft conductor(s) 136) and / or to the electrosurgical electrodes 128. As such, the ES energy conductors 662 may extend from the prongs 280 of the plug 127, through the proximal cable 258, the casing 668 of the battery module 142, and the distal cable 260 to the housing 123. For example, as shown in FIG. 6, the ES energy conductors 662 may extend continuously (e.g., uninterrupted) through the inner sheath 613, which may also extend from the plug 127 to the housing 123. In this configuration, the ES energy conductor 662 and inner sheath 613 may extend through an interior section of the casing 368, as shown in FIG. 7A and described below.

[0112] In addition, as shown in FIG. 6, the electrical cable 122 includes a number of direct current power (DC power) conductors 664 extending from the battery PCB 678 to the housing 123. The DC power conductors 664 may provide DC power from the battery 366 to the DC device 140. As such, the DC power conductors 664 may extend from the battery module 142 through the distal cable 260 to the housing 123. For example, as shown in FIG. 6, the DC power conductors 664 may extend continuously (e.g., uninterrupted) through the outer sheath 615, which may also extend from the casing 668 of the battery module 142 to the housing 123. Also as shown in FIG. 6, the inner sheath 613 and the ES energy conductors may also extend from the casing 668 of the battery module 142 to the housing 123 through the outer sheath 615. In FIG. 6, the battery PCB 678 includes a plurality of second contacts 674 configured to couple to the DC power conductors 664 .

[0113] The inner sheath 613 may be configured to bundle the ES energy conductors 662, reduce electromagnetic interference, and / or reduce short circuit conditions (e.g., due to liquid ingress). Similarly, the outer sheath 615 may be configured to bundle the DC power conductors 664 and the ES energy conductors 662, reduce electromagnetic interference, and / or reduce short circuit conditions (e.g., due to liquid ingress). Additionally, in the configuration shown in FIG. 6, the DC power conductors 664 are separated from the ES energy conductors 662 by the inner sheath 613. As such, the inner sheath 613 may help reduce electromagnetic interference and / or electrical noise arising between the ES energy conductors 662 and the DC power conductors 664.

[0114] FIG 7A illustrates an implementation of the electrical cable 122 shown in FIG 6, according to one example. FIG 7B illustrates a cross-sectional view of the electrical cable 122 through the distal cable 260. As shown in FIG 7A, the electrical cable 122 includes a plug 127, a proximal cable 258, a battery module 142, and a distal cable 260. The proximal cable 258 extends from the plug 127 to a casing 668 of the battery module 142, and the distal cable 260 extends from the battery module 142 to the housing 123. The proximal cable 258 includes an inner sheath 613 in which the ES energy conductors 662 are disposed, and the distal cable 260 includes a DC power conductor 664, an inner sheath 613, and an outer sheath 615 in which the ES energy conductors 662 are disposed. As shown in FIG. 7A, the battery 366 is coupled to a battery PCB 678 by a first contact 672, and the DC power conductor 664 is coupled to the battery PCB 678 by a second contact 674.

[0115] 7A, the inner sheath 613 (surrounding the ES energy conductors 662) extends from the plug 127 along the proximal cable 258, through the entire length of the casing 668, and along the distal cable 260. As shown in FIG. 7B, the proximal end 615A of the outer sheath 615 may include openings through which the inner sheath 613, the ES energy conductors 662, and the DC power conductors 664 may pass and enter the outer sheath 615. The proximal end 615A of the outer sheath 615 may be disposed in an interior compartment 782 defined by the casing 668. This may help reduce or prevent the risk of liquid entering the outer sheath 615 through the proximal end 615A.

[0116] As shown in FIG. 7B, in distal cable 260, ES energy conductors 662 extend within inner sheath 613, which extends within outer sheath 615, and DC power conductors 664 extend within outer sheath 615 and outside of inner sheath 613.

[0117] 6 and 7A, the plug 127 may include a plurality of prongs 280 configured to be received in respective sockets of the connector 120 of the electrosurgical generator 110, as described above. The prongs 280 may be provided in a quantity corresponding to the quantity of the ES energy conductors 662. In this configuration, each prong 280 may be electrically coupled to a respective one of the ES energy conductors 662 and may provide for electrically coupling each one of the ES energy conductors 662 to a respective one of the sockets of the connector 120. In the example shown in FIG. 7A, the plug 127 has three prongs 280 configured to couple to the electrosurgical generator 110. Thus, in the example of FIGS. 7A and 7B, the proximal cable 258 may include three ES energy conductors 662. Also, in the implementation of the example shown in FIGS. 7A and 7B, the distal cable 260 may include an ES energy conductor 662 for electrosurgical energy and two DC power conductors 664 for DC power. As discussed above, other examples may include different quantities of prongs 280, ES energy conductors 662, and / or DC power conductors 664.

[0118] 8A-8E show another implementation of a casing 368 of a battery module 142 that may be used with any of the electrical cables 122 shown in FIG. 3 and / or the electrical cables 122 shown in FIG. 6-7B, according to another example. In particular, FIG. 8A shows a top view of an interior compartment 882 of the casing 368 in an open state, FIG. 8B shows a bottom view of an outer surface of the casing 368 in an open state, FIG. 8C shows a first side view of the casing 368 in an open state, FIG. 8D shows a side view of a distal end of the casing 368 in an open state, and FIG. 8E shows a side view of a proximal end of the casing 368 in an open state.

[0119] 8A-8E, the casing 368 defines an interior compartment 882 configured to receive the battery 366. In the example shown in Figures 8A-8E, the casing 368 is configured to receive a single battery 366. However, as described above, in other examples, the battery 366 may include multiple batteries.

[0120] In examples, the casing 368 may be actuated from the open state shown in FIGS. 8A and 8B to the closed state. As explained above, when the casing 368 is in the open state, the casing 368 may allow access to the interior compartment 882, and when the casing 368 is in the closed state, the casing 368 may inhibit or prevent access to the interior compartment 882. In some examples, the casing 368 may be configured to be actuated between the closed state and the open state multiple times to facilitate inserting, removing, and / or replacing the battery 366 in the interior compartment 882 of the casing 368. However, in other examples, including the examples shown in FIGS. 8A and 8B, the battery 366 may not be replaceable, and the casing 368 may be configured such that the casing 368 may be actuated from the open state to the closed state, but may not be returned from the closed state to the open state. In this manner, the casing 368 inhibits access to the battery 366 in the interior compartment 882.

[0121] To facilitate actuation of the casing 368 between the open and closed states, the casing 368 may include multiple sections 868A, 868B that are movable relative to one another. For example, in FIGS. 8A-8E, the casing 368 includes a first section 868A and a second section 868B that are hinged to one another. When the casing 368 is in the closed state, the first section 868A and the second section 868B may define an interior compartment 882. To secure the casing 368 in the closed state, the casing 368 may include a locking mechanism. As an example, in FIGS. 8A-8E, the locking mechanism includes one or more latches 886A on the second section 868B that can engage with respective detent(s) 886B on the first section 868A to permanently hold the casing 368 in the closed state. In other examples, the locking mechanism may additionally or alternatively include at least one of the group consisting of a slide latch, a threaded connection, a mechanical fastener (e.g., a screw), a spring latch, and a lock and key mechanism. As discussed above, in other examples, the locking mechanism may alternatively be configured to provide a releasable coupling between the first section 868A and the second section 868B.

[0122] As described above, the battery module 142 may also include the power driver circuit 370 in the interior compartment 882 of the casing 368 for the implementation of the battery module 142 shown in FIG. 3, or the battery module 142 may include the battery PCB 678 for the implementation of the battery module 142 shown in FIG. 6. The power driver circuit 370 and / or the battery PCB 678 may be fixedly coupled to the first section 868A and / or the second section 868B of the casing 368. In the example shown in FIGS. 8A-8E, the first section 868A may have a generally flat surface that may aid in mounting the battery PCB 678 or the power driver circuit 370 to the casing 368. In contrast, the second section 868B may have a rounded contour, which may help support a cylindrically shaped battery in the interior compartment 882. However, in other examples, the first section 868A and / or the second section 868B may have different shapes and / or the battery PCB 678 or the power driver circuit 370 may be coupled to the second section 868B.

[0123] Although not shown in FIGS. 8A-8E , the battery module 142 may additionally include one or more battery retaining clips (e.g., battery retaining clip(s) 484 shown in FIGS. 4A and 4E ) coupled to the first section 868A and / or the second section 868B. The one or more battery retaining clips may help inhibit the battery 366 from inadvertently falling out of the battery module 142 when the casing 368 is in the open configuration. While the one or more battery retaining clips may provide certain advantages, in other examples, the battery module 142 may omit the battery retaining clip(s).

[0124] 8D and 8E, the casing 368 may include a first opening at a proximal end of the casing 368 and a second opening at a distal end of the casing 368. The first opening is configured to receive the proximal cable 258 such that the proximal cable 258 extends through the first opening and into the interior compartment 882 of the casing 368, and the second opening is configured to receive the distal cable 260 such that the distal cable 260 extends through the second opening and into the interior compartment 882 of the casing 368.

[0125] 8E, the first section 868A may include a first recess 894A at a proximal end of the casing 368, and the second section 868B may include a second recess 894B at a proximal end of the casing 368. When the casing 368 is in the closed state, the first recess 894A and the second recess 894B are aligned with one another to define a first opening through the proximal end of the casing 368. In addition, the first recess 894A and the second recess 894B may be configured to apply a clamping force to the proximal cable 258 to help reduce forces pulling the proximal cable 258 outwardly away from the casing 368.

[0126] 8D , the second section 868B may include a third recess 896A at a distal end of the casing 368, and the second section 868B may include a fourth recess 896B at a distal end of the casing 368. When the casing 368 is in the closed state, the third recess 896A and the fourth recess 896B are aligned with one another to define a second opening through the distal end of the casing 368. In addition, the third recess 896A and the fourth recess 896B may be configured to apply a clamping force to the distal cable 260 to help reduce forces pulling the distal cable 260 outwardly away from the casing 368.

[0127] In this configuration, when the casing 368 is in the closed state, the first opening of the casing 368 (defined by the first recess 894A and the second recess 894B) may have a smaller circumference than the circumference of the proximal cable 258 to apply a clamping force to the proximal cable 258. Similarly, when the casing 368 is in the closed state, the second opening of the casing 368 (defined by the third recess 896C and the fourth recess 896B) may have a smaller circumference than the circumference of the distal cable 260 to apply a clamping force to the distal cable 260.

[0128] In some examples, the casing 368 may additionally or alternatively include a first strain relief structure 897 to assist in reducing strain on the proximal cables 258 and / or a second strain relief structure 898 to assist in reducing strain on the distal cables 260. As an example, in FIG. 8A , the casing 368 includes a first strain relief structure 897 at a location in the interior compartment 882 adjacent a first opening at the proximal end of the casing 368 and a second strain relief structure 898 at a location in the interior compartment 482 adjacent a second opening at the distal end of the casing 368. For example, in an implementation that includes a battery PCB 678, the first strain relief structure 897 may be between the battery PCB 678 and the first opening at the proximal end of the casing 368 and the second strain relief structure 898 may be between the battery PCB 678 and the second opening at the distal end of the casing 368. In an implementation that includes a power driver circuit 370, the first strain relief structure 897 may be between the power driver circuit 370 and a first opening at the proximal end of the casing 368, and the second strain relief structure 898 may be between the power driver circuit 370 and a second opening at the distal end of the casing 368.

[0129] 8A, the first strain relief structure 897 may include one or more baffles that define a non-linear path for the proximal cable 258 through the interior compartment 882. For example, in FIG. 8A, the first strain relief structure 897 includes a first baffle 897A that extends in a first direction that is transverse to a central axis of a first opening at the proximal end of the casing 368. Additionally, the first strain relief structure 897 includes a second baffle 897B that is distal to the first baffle 897A and extends in a second direction that is transverse to the central axis of the first opening. The first baffle 897A is configured to direct the proximal cables 258 in a first direction and the second baffle 897B is configured to direct the proximal cables 258 in a second direction such that the first strain relief structure 897 forms a bend in the proximal cables 258 passing through the first strain relief structure 897. By forming a bend around one or more baffles, the first strain relief structure 897 may help reduce strain and / or reduce forces that may pull the proximal cables 258 outwardly away from the casing 368.

[0130] Additionally, in this example, the second strain relief structure 898 may include one or more baffles that define a non-linear path for the distal cable 260 in the interior compartment 882. For example, in FIG. 8A , the second strain relief structure 898 includes a third baffle 898A that extends in a third direction that is transverse to a central axis of the second opening at the proximal end of the casing 368. Additionally, the second strain relief structure 898 includes a fourth baffle 898B that is proximal to the third baffle 898A and extends in a fourth direction that is transverse to the central axis of the second opening. The third baffle 898A is configured to direct the distal cable 260 in a third direction and the fourth baffle 898B is configured to direct the distal cable 260 in a fourth direction such that the second strain relief structure 898 forms a bend in the distal cable 260 passing through the second strain relief structure 898. By forming a bend around one or more baffles, the second strain relief structure 898 can help reduce strain and / or reduce forces that may pull the distal cable 260 outwardly away from the casing 368.

[0131] 8A, the first baffle 897A and the third baffle 898A extend from the proximal and distal ends, respectively, to a point where the first baffle 897A and the third baffle 898B are perpendicular to the first and second openings, respectively. This may help to enhance the strain relief and cable retention provided by the first strain relief structure 897 and the second strain relief structure 898. Furthermore, the first baffle 897A and the third baffle 898B may have a curved shape such that a gap is formed between the first baffle 897A and the proximal cables 258 and a gap is formed between the third baffle 898A and the distal cables 260. This may help to enhance the strain relief and cable retention provided by the first strain relief structure 897 and the second strain relief structure 898.

[0132] 9, a flow diagram of a process 900 for operating an electrosurgical instrument is shown, according to one example. At block 910, the process 900 includes coupling an electrosurgical instrument to an electrosurgical generator. The electrosurgical instrument includes (i) a housing extending from a proximal end to a distal end, (ii) an electrosurgical electrode extending from the distal end of the housing, and (iii) an electrical cable extending from the proximal end of the housing. The electrical cable is configured to deliver electrosurgical energy from the electrosurgical generator. The electrosurgical electrode is configured to use the electrosurgical energy for at least one of cutting or coagulating tissue. The electrical cable includes (a) a plug configured to electrically couple to the electrosurgical generator, (b) a proximal cable including a plurality of first conductors extending from the plug to a battery module, and (c) a distal cable including a plurality of second conductors extending from the battery module to the housing. The plurality of first conductors includes a first quantity of conductors and the plurality of second conductors includes a second quantity of conductors, the first quantity being less than the second quantity.

[0133] The battery module includes a casing defining an interior compartment configured to receive a battery, and a power driver circuit in the interior compartment of the casing, the power driver circuit including (i) a first set of contacts electrically coupled to a plurality of first conductors, (ii) a second set of contacts electrically coupled to a plurality of second conductors, and (iii) a third set of contacts electrically coupled to the battery.

[0134] At block 912, the process 900 also includes transmitting electrosurgical energy from the electrosurgical generator to the electrosurgical electrodes via the proximal and distal cables. At block 914, the process 900 includes performing an electrosurgical procedure using the electrosurgical energy at the electrosurgical electrodes. At block 916, the process 900 includes transmitting direct current (DC) power from a battery to a DC powered device.

[0135] 10, a flow diagram of a process 1000 for forming an electrosurgical instrument is shown, according to one example. At block 1010, the process 1000 includes forming a housing extending from a proximal end to a distal end. At block 1012, the process 1000 includes coupling an electrosurgical electrode to the distal end of the housing. The electrosurgical electrode is configured to use electrosurgical energy for at least one of cutting or coagulating tissue. At block 1014, the process 1000 includes forming an electrical cable configured to deliver electrosurgical energy from an electrosurgical generator.

[0136] The electrical cable includes (I) a plug configured to electrically couple to an electrosurgical generator, (II) a proximal cable including a plurality of first conductors extending from the plug to a battery module, and (III) a distal cable including a plurality of second conductors extending from the battery module to a housing, the plurality of first conductors including a first quantity of conductors and the plurality of second conductors including a second quantity of conductors, the first quantity being less than the second quantity.

[0137] The battery module includes (a) a casing defining an interior compartment configured to receive a battery, and (b) a power driver circuit in the interior compartment of the casing. The power driver circuit includes (i) a first set of contacts electrically coupled to a plurality of first conductors, (ii) a second set of contacts electrically coupled to a plurality of second conductors, and (iii) a third set of contacts electrically coupled to the battery.

[0138] 11, a flow diagram of a process 1100 for operating an electrosurgical instrument is shown according to another example. At block 1110, the process 1100 includes coupling an electrosurgical instrument to an electrosurgical generator. The electrosurgical instrument includes (i) a housing extending from a proximal end to a distal end, (ii) an electrosurgical electrode extending from the distal end of the housing, and (iii) an electrical cable extending from the proximal end of the housing. The electrical cable is configured to deliver electrosurgical energy from the electrosurgical generator. The electrosurgical electrode is configured to use the electrosurgical energy for at least one of cutting or coagulating tissue.

[0139] The electrical cable includes a plug configured to electrically couple to an electrosurgical generator. The electrical cable also includes a battery module including (i) a casing defining an internal compartment configured to receive a battery, and (ii) a battery PCB in the internal compartment of the casing. The battery PCB includes a first set of contacts configured to electrically couple the battery to the battery PCB. The electrical cable also includes a proximal cable extending from the plug to the battery module, a distal cable extending from the battery module to the housing, a plurality of ES energy conductors extending the entire length of the electrical cable between the plug and the housing, and a plurality of DC power conductors extending from the battery PCB to the housing.

[0140] At block 1112, the process 1100 also includes transmitting electrosurgical energy from the electrosurgical generator to the electrosurgical electrodes via the proximal and distal cables. At block 1114, the process 1100 includes performing an electrosurgical procedure using the electrosurgical energy at the electrosurgical electrodes. At block 1116, the process 900 includes transmitting DC power from the battery to a DC powered device.

[0141] 12, a flow diagram of a process 1200 for forming an electrosurgical instrument is shown, according to one example. At block 1210, the process 1200 includes forming a housing extending from a proximal end to a distal end. At block 1212, the process 1200 includes coupling an electrosurgical electrode to the distal end of the housing. The electrosurgical electrode is configured to use electrosurgical energy to at least one of cut or coagulate tissue. At block 1214, the process 1200 includes forming an electrical cable configured to deliver electrosurgical energy from an electrosurgical generator.

[0142] The electrical cable includes a plug configured to electrically couple to an electrosurgical generator. The electrical cable also includes a battery module including (i) a casing defining an internal compartment configured to receive a battery, and (ii) a battery PCB in the internal compartment of the casing. The battery PCB includes a first set of contacts configured to electrically couple the battery to the battery PCB. The electrical cable also includes a proximal cable extending from the plug to the battery module, a distal cable extending from the battery module to the housing, a plurality of ES energy conductors extending the entire length of the electrical cable between the plug and the housing, and a plurality of DC power conductors extending from the battery PCB to the housing.

[0143] While different advantageous configurations have been described for purposes of illustration and explanation, these configurations are not intended to be exhaustive or to limit the examples to the disclosed forms. Many modifications and variations will be apparent to those skilled in the art. Moreover, different advantageous examples may demonstrate different advantages over other advantageous examples. The selected example or examples have been chosen and described to illustrate the principles and practical applications of the examples, and to enable those skilled in the art to understand the disclosure of the various examples with various modifications as appropriate for the particular use envisaged.

[0144] It is also contemplated that any feature of any of the described variations of the invention may be disclosed and claimed independently or in combination with any one or more of the features described herein. Similarly, a reference to a singular item includes the possibility that there are plurals of the same items. More specifically, as used in this specification and the appended claims, the singular forms "a," "and," "said," and "the" include plural references unless the context dictates otherwise. It is further noted that the claims may be drafted to exclude any optional element. As such, this specification is intended as a predicate for the use of exclusive terms such as "solely" and "only" in connection with the recitation of claim elements, or the use of "negative" limitations. Unless otherwise defined herein, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The scope of this application should not be limited by this specification, but only by the plain meaning of the claim terms employed.

Claims

1. 1. An electrosurgical instrument comprising: a housing extending from a proximal end to a distal end; an electrosurgical electrode extending from the distal end of the housing, the electrosurgical electrode configured to use electrosurgical energy to at least one of cut or coagulate tissue; an electrical cable extending from the proximal end of the housing, the electrical cable configured to deliver the electrosurgical energy from an electrosurgical generator; The electrical cable comprises: a plug configured to electrically couple to the electrosurgical generator; a battery module including: (i) a casing defining an interior compartment configured to receive a battery; and (ii) a battery printed circuit board (PCB) in the interior compartment of the casing, the battery PCB including a first set of contacts configured to electrically couple a battery to the battery PCB; a proximal cable extending from the plug to a battery module; a distal cable extending from the battery module to the housing; a plurality of electrosurgical energy (ES energy) conductors extending the entire length of the electrical cable between the plug and the housing; a plurality of direct current (DC) power conductors extending from the battery PCB to the housing; an inner sheath extending from the plug to the housing, the plurality of ES energy conductors extending continuously through the inner sheath, the inner sheath bundling the plurality of ES energy conductors, the plurality of ES energy conductors and the inner sheath passing through the entire interior compartment of the casing from the plug along the proximal cable and extending continuously along the distal cable to the housing; an outer sheath extending from the casing to the housing of the battery module, wherein the plurality of DC power conductors, the inner sheath, and the plurality of ES energy conductors extend through the outer sheath along the distal cable from the casing to the housing; Including, An electrosurgical instrument, wherein the inner sheath separates the plurality of ES energy conductors from the plurality of DC power conductors along the distal cable.

2. 10. The method of claim 1, wherein the battery PCB includes a plurality of second contacts configured to couple to the plurality of DC power conductors.

3. 3. The electrosurgical instrument of claim 1, wherein a proximal end of the outer sheath includes openings through which the inner sheath, the plurality of ES energy conductors, and the plurality of DC power conductors enter the outer sheath, the proximal end of the outer sheath being disposed within the interior compartment defined by the casing.

4. the casing includes a first section and a second section hinged to one another; The electrosurgical instrument of claim 1 or 2, wherein the first section and the second section are configured to move between an open state that provides access to the interior compartment of the casing and a closed state that prevents access to the interior compartment of the casing.

5. the first section includes a first recess at the proximal end of the casing, and the second section includes a second recess at the proximal end of the casing; When the casing is in the closed state, the first recess and the second recess define a first opening through the proximal end of the casing and are configured to apply a clamping force to the proximal cable; the second section includes a third recess at the distal end of the casing, and the second section includes a fourth recess at the distal end of the casing; The electrosurgical instrument according to claim 4, wherein when the casing is in the closed condition, the third recess and the fourth recess define a second opening through the distal end of the casing and are configured to apply a clamping force to the distal cable.

6. 6. The electrosurgical instrument according to claim 5, wherein the battery module further comprises a first strain relief structure at a location in the internal compartment adjacent the first opening at the proximal end of the casing, and a second strain relief structure at a location in the internal compartment adjacent the second opening at the distal end of the casing.

7. The electrosurgical instrument according to claim 6, wherein the first strain relief structure includes one or more baffles that define a non-linear path for the proximal cable through the internal compartment, and the second strain relief structure includes one or more baffles that define a non-linear path for the distal cable in the internal compartment.

8. the first strain relief structure includes a first baffle extending in a first direction transverse to a central axis of the first opening at the proximal end of the casing, and a second baffle distal to the first baffle and extending in a second direction transverse to the central axis of the first opening; 8. The electrosurgical instrument according to claim 7, wherein the first baffle is configured to direct the proximal cable in the first direction and the second baffle is configured to direct the proximal cable in the second direction such that the first strain relief structure forms a bend in the proximal cable passing through the first strain relief structure.

9. the second strain relief structure includes a third baffle extending in a third direction transverse to a central axis of the second opening at the proximal end of the casing, and a fourth baffle proximal to the third baffle extending in a fourth direction transverse to the central axis of the second opening; 8. The electrosurgical instrument according to claim 7, wherein the third baffle is configured to direct the distal cable in the third direction and the fourth baffle is configured to direct the distal cable in the fourth direction such that the second strain relief structure forms a bend in the distal cable passing through the second strain relief structure.

10. An electrosurgical instrument as described in claim 4, wherein the first section has a generally flat surface and the battery PCB is bonded to the generally flat surface of the first section.

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