Electrosurgical tool, method of use, and method of manufacture

Abstract

In one example, an electrosurgical tool includes a handle that defines an internal cavity, a power cord coupled to an electrosurgical generator and configured to receive electrosurgical energy from the electrosurgical generator, and a shaft extending distally from the internal cavity of the handle. The shaft defines an internal bore. The electrosurgical tool also includes a printed circuit board disposed within the internal bore of the shaft. The printed circuit board is electrically coupled to the power cord. The printed circuit board is configured to conduct electrosurgical energy from the power cord to the inner surface of the shaft. The shaft is movable relative to the handle and the printed circuit board. The electrosurgical tool also includes an electrosurgical electrode extending distally from the distal end of the shaft. The shaft is configured to conduct electrosurgical energy to the electrosurgical electrode.

Description

Technical Field

[0001] Cross - Reference to Related Applications This application claims the benefit of priority of U.S. Provisional Patent Application No. 63 / 342,611, filed on May 16, 2022, the entire contents of which are incorporated herein by reference.

[0002] The present disclosure generally relates to electrosurgery, and more particularly, to electrosurgical tools and methods for transmitting electrosurgical energy through electrosurgical tools.

Background Art

[0003] In electrosurgery, a high - frequency (RF) current (also referred to as electrosurgical energy) is applied to biological tissue during an electrosurgical procedure to cut, coagulate, or modify the biological tissue. Specifically, an electrosurgical generator generates a current and supplies it to an active electrode, and the active electrode applies the current (and thus, 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., by the principle of resistive heating), which raises the temperature of the tissue and induces modification of the tissue (e.g., cutting, coagulation, ablation, and / or sealing of the tissue).

Summary of the Invention

[0004] In one example, an electrosurgical tool includes a handle that defines an internal cavity, a power cord coupled to an electrosurgical generator and configured to receive electrosurgical energy from the electrosurgical generator, and a shaft extending distally from the internal cavity of the handle. The shaft defines an internal bore. The electrosurgical tool also includes a printed circuit board disposed within the internal bore of the shaft. The printed circuit board is electrically coupled to the power cord. The printed circuit board is configured to conduct electrosurgical energy from the power cord to the inner surface of the shaft. The shaft is movable relative to the handle and the printed circuit board. The electrosurgical tool also includes an electrosurgical electrode extending distally from the distal end of the shaft. The shaft is configured to conduct electrosurgical energy to the electrosurgical electrode.

[0005] In another example, a method of operating an electrosurgical tool includes coupling a power cord of the electrosurgical tool to an electrosurgical generator. The electrosurgical tool includes a handle that defines an internal cavity and a shaft extending distally from the internal cavity of the handle. The shaft defines an internal bore. The electrosurgical tool also includes a printed circuit board disposed within the internal bore of the shaft. The printed circuit board is electrically coupled to the power cord. The printed circuit board is configured to conduct electrosurgical energy from the power cord to the inner surface of the shaft. The shaft is movable relative to the handle and the printed circuit board. The electrosurgical tool also includes an electrosurgical electrode extending distally from the distal end of the shaft.

[0006] The method also includes using the power cord to supply electrosurgical energy from the electrosurgical generator to the printed circuit board. The method also includes supplying, by the printed circuit board, electrosurgical energy from the power cord to the inner surface of the shaft. The method further includes conducting electrosurgical energy from the shaft to the electrosurgical electrode.

[0007] In another example, a method of manufacturing an electrosurgical tool includes forming a housing comprising a handle that defines an internal cavity and a shaft that extends distally from the internal cavity of the handle. The shaft defines an internal bore. The method also includes placing a printed circuit board within the internal bore of the shaft and electrically coupling the printed circuit board to a power cord. The power cord is coupled to an electrosurgical generator and configured to receive electrosurgical energy from the electrosurgical generator. The shaft is movable relative to the handle and the printed circuit board. The method also includes electrically coupling the printed circuit board to an inner surface of the shaft and electrically coupling an electrosurgical electrode to a distal end of the shaft. The shaft is configured to conduct electrosurgical energy to the electrosurgical electrode.

[0008] New features considered characteristic of the illustrative examples are set forth in the appended claims. However, for a better understanding, together with the accompanying drawings, reference should be made to the following detailed description of the illustrative examples of the present disclosure regarding preferred usage modes, other objectives, and the description.

Brief Description of the Drawings

[0009]

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DETAILED DESCRIPTION OF THE INVENTION

[0010] Hereinafter, some of the attached drawings, which do not show all of the disclosed examples, will be referred to to explain the disclosed examples in more detail. In fact, a plurality of different examples can be described, but these should not be construed as being limited to the examples described herein. Rather, these examples are provided to explain the present disclosure thoroughly and completely so that the scope of the present disclosure is fully conveyed to those skilled in the art.

[0011] The terms "approximately" or "substantially" with respect to quantities or measurements described herein do not require exact realization of the recited characteristics, parameters, or values, while allowing for deviations or variations including, for example, tolerances, measurement errors, measurement accuracy limits, and other factors known to those skilled in the art, that can be an amount that does not preclude the intended effect of the characteristic.

[0012] As described above, in an electrosurgical tool, electrosurgical energy can be applied from an electrosurgical electrode to tissue using electrical energy supplied by an electrosurgical generator. For this reason, an electrosurgical tool generally includes a housing in which one or more conductors for supplying electrosurgical energy to the electrosurgical electrode are disposed. Some electrosurgical tools include a shaft that is axially adjustable relative to the housing (e.g., the shaft may be telescopically movable relative to the housing). This can facilitate adjusting the length of the electrosurgical tool to handle target tissues of different sizes and / or shapes.

[0013] In addition, some electrosurgical tools enable rotation of the electrosurgical electrode relative to the housing. This can facilitate adjustment of the angle of the electrosurgical electrode with respect to one or more user input devices of the electrosurgical tool. In this configuration, the user can comfortably grip the housing at a position where the user input device can be comfortably operated with a finger, with the electrosurgical electrode set at a rotational position selected from a plurality of rotational positions relative to the housing, for example, based on the position, size, and / or shape of the surgical site where the surgery is being performed.

[0014] However, enabling axial movement and / or rotation of the electrosurgical electrode relative to the housing can complicate the design and increase manufacturing costs. For example, when the electrosurgical electrode rotates relative to the housing and / or moves axially relative to the housing, it can be difficult to maintain an electrical connection between the electrical components within the housing and the electrosurgical electrode. This problem can be further exacerbated when the electrosurgical tool includes other features distal to the housing, such as a light source, one or more optical components, and / or a smoke evacuation mechanism.

[0015] The present application provides an electrosurgical tool, a method of using the electrosurgical tool, and a method of manufacturing the electrosurgical tool that can address at least some of the above-described problems. For example, in one instance, the electrosurgical tool can include a printed circuit board within an inner bore of a shaft extending distally from an internal cavity of the housing. The printed circuit board can conduct electrosurgical energy from a power cord to an inner surface of the shaft. The shaft can be movable relative to the housing and the printed circuit board. The electrosurgical electrode extends distally from a distal end of the shaft and can receive electrosurgical energy from the shaft. In this configuration, the printed circuit board and the shaft can maintain an electrical connection between the electrosurgical electrode and an electrosurgical energy source (e.g., an electrosurgical generator) at a plurality of rotational orientations and / or axial positions of the electrosurgical electrode relative to the housing.

[0016] Referring to FIG. 1, an electrosurgical system 100 according to an example is shown. As shown in FIG. 1, the electrosurgical system 100 includes an electrosurgical generator 110 and an electrosurgical tool 112. Generally, the electrosurgical generator 110 can generate electrosurgical energy suitable for performing electrosurgery on a patient. For example, the electrosurgical generator 110 may include a power conversion circuit 114 that can convert grid power into electrosurgical energy such as high-frequency (RF) output power. As an example, the power conversion circuit 114 may 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.

[0017] In an example, the electrosurgical generator 110 may include a user interface 116 that can receive one or more inputs from a user and / or provide one or more outputs to the user. As an 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 touchscreens, one or more display screens, one or more indicator lights, one or more speakers, and / or one or more tactile output devices.

[0018] In an example, the user interface 116 may be operable to select one from a plurality of operating modes of the electrosurgical generator 110. As an example, the operating modes may include a cutting mode, a coagulation mode, an ablation mode, and / or a sealing mode. It is also possible to generate a mixed mode by forming a combination of these waveforms. In one embodiment, the operating mode may correspond to each waveform of the electrosurgical energy. Therefore, in this embodiment, the electrosurgical generator 110 can 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.

[0019] In addition, the electrosurgical generator 110 may include one or more generator sensors 118 capable of detecting one or more states associated with the electrosurgical energy and / or the target tissue. By way of example, the generator sensors 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 an example, the electrosurgical generator 110 may generate electrosurgical energy having an amount of electrosurgical energy (e.g., power) and / or a waveform selected from a plurality of waveforms based on one or more parameters associated with the states detected by the generator sensors 118, as an addition or alternative to the above.

[0020] In one example, the electrosurgical energy may have a frequency higher than about 100 kilohertz (kHz) to suppress (or avoid) the stimulation of muscles and / or nerves near the target tissue. In another example, the electrosurgical energy may have a frequency of about 300 kHz to about 500 kHz.

[0021] In FIG. 1, the electrosurgical generator 110 further includes a connector 120 that may facilitate the connection of the electrosurgical generator 110 to the electrosurgical tool 112. For example, the electrosurgical tool 112 may include a power cord 122 having a plug that can be coupled to the socket of the connector 120 of the electrosurgical generator 110. In this configuration, the electrosurgical generator 110 can supply electrosurgical energy to the electrosurgical tool 112 through the connection between the connector 120 of the electrosurgical generator 110 and the power cord 122 of the electrosurgical tool 112.

[0022] The electrosurgical generator 110 may further include a controller 141 capable of controlling the operation of the electrosurgical generator 110. In an example, the controller 141 can be implemented using hardware, software, and / or firmware. For instance, the controller 141 may include one or more processors and a non-transitory computer-readable medium (e.g., volatile and / or non-volatile memory) storing machine language instructions or other executable instructions. When executed by one or more processors, these instructions cause the electrosurgical generator 110 to perform various operations described herein. Thus, the controller 141 can also receive data and store the data in memory. As shown in FIG. 1, the controller 141 can be communicatively coupled to the power conversion circuit 114, the user interface 116, the generator sensor 118, and / or the connector 120.

[0023] As shown in FIG. 1, the electrosurgical tool 112 may include a housing 123. The housing 123 can be an elongated structure in which or on which the components of the electrosurgical tool 112 can be disposed. In some examples, the housing 123 can be a single-piece integrated structure. In other examples, the housing 123 can include a plurality of structures coupled to each other.

[0024] In FIG. 1, the housing 123 includes a handle 124 that defines an internal cavity 252 (shown, for example, in FIGS. 2 and 4), a shaft 126 that extends distally from the handle 124 and defines an internal bore 254 (shown, for example, in FIGS. 2 and 4), and a monopolar electrosurgical electrode 128 that extends distally from the shaft 126. Generally, the handle 124 can be configured to facilitate gripping and manipulation of the electrosurgical tool 112 by a user during the performance of electrosurgery. For example, the handle 124 can have a shape and / or size that facilitates the performance of electrosurgery by the user by operating the electrosurgical tool 112 with one hand. In one embodiment, the handle 124 can have a shape and / or size that facilitates holding of the electrosurgical tool 112 by a user in a manner similar to gripping a writing utensil (for example, the electrosurgical tool 112 can be an electrosurgical pencil).

[0025] Also, for example, the handle 124 and / or the shaft 126 can include one or more materials (such as a plastic material) that are electrical insulators. This can facilitate insulating the user from the electrosurgical energy that flows through the electrosurgical tool 112 during the performance of electrosurgery. As will be described in more detail below, at least a portion of the shaft 126 is formed of a conductive material so that the shaft 126 can conduct electrosurgical energy to the monopolar electrosurgical electrode 128.

[0026] In some embodiments, the shaft 126 can be coupled to the handle 124 such that it is fixed and immovable. For example, by simplifying electrical connections that may otherwise require consideration of movement of the shaft 126 and the handle 124 relative to each other (e.g., by omitting slip ring electrical contacts and / or sliding electrical contacts), manufacturing can be simplified and manufacturing costs can be reduced. In one example, the handle 124 and the shaft 126 can be formed as a single unitary structure such that they are fixed and immovable relative to each other. In another example, the handle 124 and the shaft 126 can be fixedly coupled to each other by a welded joint, an adhesive joint, and / or another joint that prevents movement between the handle 124 and the shaft 126.

[0027] In other embodiments, the shaft 126 can be movable relative to the handle 124 along the longitudinal axis of the electrosurgical tool 112. For example, the shaft 126 can be movably nested within an internal cavity 252 defined by the handle 124 such that it extends distally and retracts proximally relative to the handle 124 (e.g., it can be movable along the longitudinal axis of the electrosurgical tool 112). The monopolar electrosurgical electrode 128 is coupled to the shaft 126 and is thus axially movable along the longitudinal axis together with the shaft 126 relative to the handle 124. This enables adjustment of the length of the electrosurgical tool 112, facilitating performance of electrosurgery at multiple different depths within tissue (e.g., due to different anatomical shapes and / or sizes of patients) and / or at multiple different angles.

[0028] In some embodiments, the monopolar electrosurgical electrode 128 may be rotatable about an axis of rotation parallel to the longitudinal axis of the electrosurgical tool 112, as an addition or alternative to the above. In some examples, the monopolar electrosurgical electrode 128 may be rotatable relative to the handle 124 and the shaft 126. In other examples, the monopolar electrosurgical electrode 128 may be fixed in the rotational direction relative to the shaft 126 such that the shaft 126 and the monopolar electrosurgical electrode 128 rotate integrally relative to the handle 124. By rotating the monopolar electrosurgical electrode 128 relative to the handle 124, it may be facilitated to adjust the angle of the monopolar electrosurgical electrode 128 relative to one or more user input devices 130 of the electrosurgical tool 112. In this configuration, the user can comfortably grip the handle 124 at a position where the user can comfortably operate the user input device 130 with a finger, with the monopolar electrosurgical electrode 128 set at a rotational position selected from a plurality of rotational positions relative to the handle 124, for example, based on the position, size, and / or shape of the surgical site where the surgery is being performed.

[0029] In one embodiment, the monopolar electrosurgical electrode 128 may be rotatable more than 360° relative to the handle 124. This allows for improved usability as the operator can freely rotate the monopolar electrosurgical electrode 128 without limitation. However, in other embodiments, the monopolar electrosurgical electrode 128 may be rotatable by 360° or less (e.g., a 180° rotation or a 360° rotation). Even in this case, the operator can still achieve the desired rotational configuration and may do so by rotating in a first direction and then reverse-rotating in a second direction after reaching a stopper that limits further rotation.

[0030] Allowing rotation of the monopolar electrosurgical electrode 128 relative to the handle 124 and / or the shaft 126 can be beneficial, although in some embodiments, the monopolar electrosurgical electrode 128 can be fixed in the rotational direction relative to the handle 124 and the shaft 126. For example, this can simplify manufacturing and reduce manufacturing costs by simplifying the electrical connections (e.g., by omitting slip ring electrical contacts and / or sliding electrical contacts) that may otherwise be necessary to account for movement of the shaft 126 and handle 124 relative to each other.

[0031] The user input device 130 can select the operating mode of the electrosurgical tool 112 and / or the electrosurgical generator 110. For example, in one embodiment, the user input device 130 can be configured to select a cutting operating mode and a coagulation operating mode. In response to actuation of the user input device 130 of the electrosurgical tool 112, the electrosurgical tool 112 can (i) receive electrosurgical energy at a power level and / or waveform corresponding to the operating mode selected via the user input device 130 and (ii) supply the electrosurgical energy to the monopolar electrosurgical electrode 128.

[0032] In FIG. 1, the electrosurgical tool 112 includes a plurality of electrical components that facilitate the supply of electrosurgical energy received from the electrosurgical generator 110 to the monopolar electrosurgical electrode 128. For example, at least a portion of the shaft 126 is formed of a conductive material such that the shaft 126 is electrically coupled to the monopolar electrosurgical electrode 128. In one embodiment, the entire shaft 126 can be formed of a conductive material. For example, the shaft 126 can be a tubular structure entirely formed of metal. In another embodiment, the shaft 126 can include a conductive portion and an insulating portion, in which case the conductive portion is configured to conduct electrosurgical energy to the monopolar electrosurgical electrode 128.

[0033] In addition, the electrosurgical tool 112 includes a printed circuit board 132 (e.g., a flexible printed circuit board) within the inner bore 254 of the shaft 126 and / or within the internal cavity 252 of the handle 124. The printed circuit board 132 can be electrically coupled to the power cord 122 and to the shaft 126 that is electrically coupled to the monopolar electrosurgical electrode 128. In this configuration, the printed circuit board 132 and the shaft 126 provide a circuit for conducting electrosurgical energy from the power cord 122 to the monopolar electrosurgical electrode 128.

[0034] As will be described in more detail below, the electrosurgical tool 112 can include one or more components that can help maintain an electrical connection between the printed circuit board 132 and the inner surface of the shaft 126 (and thus the monopolar electrosurgical electrode 128) in a plurality of axial positions of the shaft 126 relative to the handle 124 and / or a plurality of rotational orientations of the shaft 126 relative to the handle 124 (e.g., all axial positions when the shaft 126 moves telescopically relative to the handle 124 and / or all rotational orientations when the shaft 126 rotates relative to the handle 124).

[0035] In an example, the user input device 130 may comprise one or more buttons on the outer surface of the handle 124. Each button of the user input device 130 may be operable to activate one of a plurality of switches 138 of the printed circuit board 132. Generally, the switch 138 and / or the printed circuit board 132 may be operable to control the supply of electrosurgical energy from the electrosurgical generator 110 to the monopolar electrosurgical electrode 128. For example, in one embodiment, when each button is operated (e.g., pressed), actuation of the switch 138 associated with the button causes the printed circuit board 132 to transmit a signal to the electrosurgical generator 110, and in response thereto, the electrosurgical generator 110 may be caused to supply electrosurgical energy at a power level and / or waveform corresponding to the operating mode associated with the button. In another embodiment, operation of the button and thus actuation of each switch 138 associated with the button closes the switch 138 to complete a circuit to the electrosurgical generator 110, and in response thereto, the electrosurgical generator 110 may be caused to supply electrosurgical energy at a power level and / or waveform corresponding to the operating mode associated with the button. In any of the exemplary embodiments, the electrosurgical energy supplied by the electrosurgical generator 110 may be supplied from the electrosurgical generator 110 to the monopolar electrosurgical electrode 128 by the power cord 122, the printed circuit board 132, and the shaft 126.

[0036] In FIG. 1, the electrosurgical tool 112 comprises the user input device 130, but in another example, the user input device 130 is separable from the electrosurgical tool 112. For example, additionally or alternatively, the user input device 130 may comprise one or more foot pedals operable to control the operation of the electrosurgical tool 112 as described above. The foot pedal is communicatively coupled to the electrosurgical generator 110 and can supply a signal in response to actuation of the foot pedal.

[0037] In some examples, the electrosurgical tool 112 may additionally comprise one or more light sources 140 configured to emit light. In some embodiments, the light source 140 can be disposed at the distal end of the housing 123 and / or the distal end of the shaft 126 to directly provide light in the distal direction and illuminate the surgical distal portion of the monopolar electrosurgical electrode 128.

[0038] In other embodiments, as shown in FIG. 1, the light source 140 can be optically coupled to an optical structure 142 configured to receive the light emitted by the light source 140 and transmit the light in the distal direction toward the surgical site to illuminate the surgical site during the performance of electrosurgery using the monopolar electrosurgical electrode 128. Placing the light source 140 to directly illuminate the surgical field can help, for example, reduce manufacturing costs, while using the optical structure 142 to transmit light can help improve the quality of the light transmitted from the electrosurgical tool 112 (e.g., by improving the uniformity of the light and / or suppressing heat generation).

[0039] As an example, in embodiments including the optical structure 142, the optical structure 142 can include at least one optical structure selected from the group consisting of an optical lens, a non-fiber optical waveguide, and an optical fiber. If the optical structure 142 includes an optical lens (e.g., a parabolic reflector lens, an aspherical lens, and / or a Fresnel lens), the optical structure 142 can help direct the light emitted by the light source 140 in the distal direction, thereby improving the quality of the light illuminating the surgical site. As an addition or alternative to this, the optical structure 142 can include a non-fiber optical waveguide and / or an optical fiber to transmit light over a relatively long distance within the shaft 126. For example, the optical waveguide can transmit light in the distal direction by total internal reflection. In such embodiments, the optical waveguide can be provided with a cladding and / or a void on the outer surface of the optical waveguide to facilitate total internal reflection. In some embodiments, the non-fiber optical waveguide can be formed as a single unitary structure.

[0040] In some examples, the optical structure 142 may include, as an addition or alternative to the above, other optical elements for light shaping, such as a plurality of facets, one or more prisms, and / or one or more diffraction gratings, etc. Although the optical structure 142 may help improve the quality of the light guided to the surgical site, in other examples, the electrosurgical tool 112 may omit the optical structure 142 and instead directly emit the light from the light source 140 to the surgical field without transmitting the light through the optical structure 142.

[0041] In FIG. 1, the light source 140 may be coupled to the shaft 126. Thus, the light source 140 can also move telescopically with the shaft 126 relative to the handle 124. However, in other examples, the light source 140 can be disposed within the internal cavity 252 of the handle 124 and / or coupled to the outer surface of the handle 124. By way of example, the light source 140 may comprise one or more light-emitting diodes (LEDs), organic light-emitting diodes (OLEDs), optical fibers, non-optical fiber waveguides, and / or lenses. Further, for example, the light source 140 may comprise a light-emitting diode printed circuit board (LED PCB) having one or more light sources (e.g., LEDs).

[0042] The optical structure 142 may be located at the distal end of the shaft 126. In some examples, the optical structure 142 can circumferentially surround the monopolar electrosurgical electrode 128 and emit light in the distal direction around the entire side surface of the monopolar electrosurgical electrode 128. This can help reduce dark areas (shadows) and improve the uniformity of illumination in all rotational alignments of the shaft 126 with respect to the housing 123 and / or the electrosurgical tool 112 with respect to the target tissue. However, in other examples, the optical structure 142 can extend only partially around the monopolar electrosurgical electrode 128 rather than the entire circumference.

[0043] In an embodiment including the light source 140, the user input device 130, the printed circuit board 132, the switch 138, the housing conductor 134, and / or the shaft conductor 136 can additionally supply power from a direct current (DC) power source 144 to the light source 140. In one example, the DC power source 144 can include a battery disposed within the handle 124, a plug of the power cord 122, and / or a battery receptacle disposed along the power cord 122 between the handle 124 and the plug. In FIG. 1, the electrosurgical tool 112 includes the DC power source 144, but in other examples, the DC power source 144 can be separated and distinguishable from the electrosurgical tool 112. For example, in another example, the electrosurgical generator 110 can include the DC power source 144.

[0044] Also, in an embodiment including the light source 140, the user input device 130 can be operable to cause the light source 140 to emit light. In one example, the user input device 130 can include a button that independently controls the light source 140, separate from the button that controls the electrosurgical operation mode of the electrosurgical tool 112. In another example, the user input device 130 and the printed circuit board 132 can be configured such that the operation of the light source 140 is simultaneously controlled by the operation of the button that controls the electrosurgical operation mode (for example, when the button that applies electrosurgical energy to the monopolar electrosurgical electrode 128 is operated, the light source 140 can be automatically activated to emit light).

[0045] As shown in FIG. 1, in response to an operation of a user input device 130 that activates a light source 140, a DC power supply 144 can supply power (e.g., a DC voltage) to the light source 140 via a printed circuit board 132, a housing conductor 134, and / or a shaft conductor 136. In this embodiment, one or more of the conductive elements of the housing conductor 134 can be configured to supply power from the DC power supply 144 to the light source 140 and / or to return power from the light source 140 to the DC power supply 144. Thus, the housing conductor 134 can assist in providing electrical communication between the DC power supply 144 and the light source 140 when the shaft 126 and the light source 140 move telescopically relative to the handle 124, as an addition or alternative to the above.

[0046] In the above example, although the user input device 130 on the handle 124 is operable to control the operation of the light source 140, the light source 140 can also be operated by one or more user input devices on the electrosurgical generator 110 and / or on the plug of the power cord 122 (e.g., via the user interface 116), as an addition or alternative to the above.

[0047] In an example, the electrosurgical tool 112 can include, as an addition or alternative to the above, a mechanism that can exhaust surgical smoke from the target tissue to a location external to the surgical site. Surgical smoke is a byproduct of various surgical procedures. For example, in surgery, surgical smoke may be generated as a byproduct of an electrosurgical unit (ESU), a laser, an electrocautery device, an ultrasonic device, and / or other powered surgical instruments (e.g., a bone saw and / or a drill). In some cases, surgical smoke may contain toxic gases and / or biological products resulting from tissue destruction. Also, surgical smoke may contain an unpleasant odor. For the above and other reasons, many guidelines indicate that the exposure of the surgeon to surgical smoke should be reduced or minimized.

[0048] To reduce (or minimize) exposure to surgical smoke, a smoke evacuation system may be used during surgery. Generally, the smoke evacuation system may comprise a suction pump 146 capable of generating a suction pressure and / or a vacuum pressure sufficient to draw surgical smoke away from the surgical site. In some embodiments, the smoke evacuation system may be coupled to an exhaust system (e.g., an in-wall exhaust system) that discharges surgical smoke from the operating room. In other embodiments, the smoke evacuation system may filter air containing surgical smoke and return it to the operating room. In an example, the suction pump 146 and the electrosurgical generator 110 may be provided as separate devices or incorporated into a single device (e.g., in a common housing).

[0049] As shown in FIG. 1, the shaft 126 may comprise a smoke evacuation channel 148 within an internal bore 254 of the shaft 126. The smoke evacuation channel 148 may include a smoke inlet that may extend circumferentially around a central axis of a distal portion of the monopolar electrosurgical electrode 128. In this configuration, the smoke inlet of the smoke evacuation channel may serve to receive surgical smoke into the smoke evacuation channel 148 in all rotational orientation positions of the monopolar electrosurgical electrode 128 with respect to the handle 124 and / or the electrosurgical tool 112 with respect to the target tissue. However, in another example, the smoke evacuation channel 148 may include one or more smoke inlets that do not extend circumferentially around the monopolar electrosurgical electrode 128.

[0050] In one example, the smoke exhaust channel 148 may include an outer tube separated from the optical structure 142 by a gap. For example, the shaft 126 may include a plurality of standoffs that extend between the optical structure 142 and the outer tube of the smoke exhaust channel 148 to provide a gap between the outer tube and the optical structure 142. In one embodiment, the optical structure 142 may include the standoffs such that the optical structure 142 and the standoffs are formed as a single unitary structure. In another embodiment, the standoffs may be formed as a single unitary structure with the outer tube of the smoke exhaust channel 148. In another embodiment, the standoffs are separable from the outer tube of the smoke exhaust channel 148 and the optical structure 142.

[0051] In one example, the smoke exhaust channel 148 of the shaft 126 defines a first portion of the smoke flow path, and the internal cavity 252 of the handle 124 defines a second portion of the smoke flow path. FIG. 2 is a partial cross-sectional view of the electrosurgical tool 112 according to one embodiment of this example. In this configuration, surgical smoke is received from the surgical site into the smoke exhaust channel 148 provided by the inner bore 254 of the shaft 126 and can flow proximally along the smoke exhaust channel 148 to the internal cavity 252 of the handle 124. In the internal cavity 252 of the handle 124, the smoke can further flow to the smoke tube 150 that is coupled to the proximal end of the handle 124 and configured to convey the smoke from the handle 124 to the suction pump 146.

[0052] As described above, the monopolar electrosurgical electrode 128 can apply electrosurgical energy to the target tissue to perform electrosurgery (e.g., cutting, coagulating, ablating, and / or sealing the target tissue). In an example, the monopolar electrosurgical electrode 128 includes an electrosurgical substrate formed of a conductive material. As an example, stainless steel may be possible as the conductive material.

[0053] As will be described in more detail below, the electrosurgical substrate may extend axially from the proximal end of the monopolar electrosurgical electrode 128 to the distal end of the monopolar electrosurgical electrode 128. The proximal end of the monopolar electrosurgical electrode 128 can receive electrosurgical energy from the electrosurgical tool 112 (e.g., via the housing conductor 134 and the shaft conductor 136 as described above), and the distal working portion of the monopolar electrosurgical electrode 128 can apply the electrosurgical energy to the target tissue. In one embodiment, the electrosurgical substrate may include a shank portion extending from the proximal end of the monopolar electrosurgical electrode 128 to the distal working portion of the monopolar electrosurgical electrode 128. The distal working portion can be configured to perform at least one of tissue cutting or coagulation by the electrosurgical energy received from the electrosurgical tool 112.

[0054] In some examples, the distal working portion may define an electrosurgical blade. For example, the electrosurgical blade may include (i) a first side surface, (ii) a second side surface opposite the first side surface, (iii) a first major surface extending between the first side surface and the second side surface on the first side of the electrosurgical blade, and (iv) a second major surface extending between the first side surface and the second side surface on the second side of the electrosurgical blade opposite the first side. The first side surface and the second side surface have a relatively small surface area compared to the surface areas of the first major surface and the second major surface such that the thickness of the electrosurgical blade (e.g., the dimension between the first major surface and the second major surface) is relatively small compared to the length (e.g., the dimension extending between the proximal end and the distal end of the monopolar electrosurgical electrode 128) and the width (e.g., the dimension between the first side surface and the second side surface).

[0055] Referring to FIGS. 3-13, an embodiment of the electrosurgical tool 112 according to an example is shown. FIG. 3 is a perspective view of the electrosurgical tool 112 according to this example. FIG. 4 is a cross-sectional view of the electrosurgical tool 112 passing through the longitudinal axis 350 according to this example.

[0056] As shown in FIGS. 3 and 4, the electrosurgical tool 112 includes a handle 124 that defines an internal cavity 252, and a shaft 126 that extends distally from the internal cavity 252 of the handle 124. As described above, the shaft 126 defines an internal bore 254. The shaft 126 has a longitudinal axis 350 that extends between a proximal end 126A of the shaft 126 and a distal end 126B of the shaft 126. Also, a monopolar electrosurgical electrode 128 extends distally from the distal end 126B of the shaft 126. In the present embodiment, the monopolar electrosurgical electrode 128 is directly coupled to the shaft 126 or is integrally formed with the shaft 126. However, in another embodiment, the monopolar electrosurgical electrode 128 can be indirectly coupled to the shaft 126 by an intermediate conductor so as to receive electrosurgical energy conducted by a printed circuit board 132, the shaft 126, and the intermediate conductor.

[0057] In the example shown in FIGS. 3-13, the shaft 126 is movably nested within the internal cavity 252 of the handle 124 to adjust the distance of the most distal end of the monopolar electrosurgical electrode 128 relative to the handle 124. As described above, by movably nesting the shaft 126 relative to the handle 124, it may be facilitated to adjust the length of the electrosurgical tool 112 to handle target tissues of different sizes and / or shapes. However, as described above, in other examples, the shaft 126 can be axially fixed relative to the handle 124 (e.g., fixedly coupled to the handle 124) so as not to be axially movable relative to the handle 124.

[0058] Also, in this example, the shaft 126 is rotatable relative to the handle 124. In this example, since the monopolar electrosurgical electrode 128 is fixedly coupled to the shaft 126, rotation of the shaft 126 causes corresponding rotation of the monopolar electrosurgical electrode 128 relative to the handle 124. As described above, by rotating the monopolar electrosurgical electrode 128 relative to the handle 124, it may be facilitated to adjust the angle of the monopolar electrosurgical electrode 128 relative to one or more user input devices 130 of the electrosurgical tool 112. However, as described above, in other examples, the shaft 126 may be fixed in the rotational direction relative to the handle 124 so as not to be rotatable relative to the handle 124.

[0059] In some examples, the electrosurgical tool 112 may include a collar 356 at the distal end of the handle 124. The collar 356 is rotatable relative to the handle 124 and increases and / or decreases the friction between the outer surface of the shaft 126 and the inner surface of the collar 356. Thus, the collar 356 permits and / or blocks (i) axial movement of the shaft 126 relative to the handle 124 and / or (ii) rotation of the shaft 126 and the monopolar electrosurgical electrode 128 relative to the handle 124.

[0060] As described above, in some examples, the shaft 126 may be rotatable relative to the handle 124 while one or more components within the internal bore 254 of the shaft 126 are fixed in the rotational direction relative to the handle 124. For example, as will be described in more detail below, the electrosurgical tool 112 may further include a smoke exhaust channel 148, a light source 140, and an optical structure 142, and these components may be fixed in the rotational direction relative to the handle 124. Making the monopolar electrosurgical electrode 128 rotatable together with the shaft 126 while fixing the smoke exhaust channel 148, the light source 140, and / or the optical structure 142 in the rotational direction may serve to simplify the design of the electrosurgical tool 112 and / or reduce the manufacturing cost.

[0061] In some examples, the rotational configuration of the above components of the electrosurgical tool 112 can be at least partially realized as a result of (i) the shaft 126 conducting electrosurgical energy to the monopolar electrosurgical electrode 128, and (ii) the corresponding rotation of the monopolar electrosurgical electrode 128 relative to the handle 124 being caused by the rotation of the shaft 126 relative to the handle 124, with the monopolar electrosurgical electrode 128 extending distally from the distal end 126B of the shaft 126. For example, at least a portion of the shaft 126 can be formed of a conductive material so that the shaft 126 can supply electrosurgical energy to the monopolar electrosurgical electrode 128.

[0062] In one example, the monopolar electrosurgical electrode 128 and the shaft 126 are formed as a single structure of a single component. This can be beneficial in one embodiment where the monopolar electrosurgical electrode 128 is permanently fixed to the shaft 126 so that the monopolar electrosurgical electrode 128 cannot be replaced with another monopolar electrosurgical electrode 128. In another example, the monopolar electrosurgical electrode 128 and the shaft 126 can be separate components that are coupled to each other (e.g., by welding, soldering, and / or friction fit coupling). In some embodiments where the monopolar electrosurgical electrode 128 and the shaft 126 are separate components, the monopolar electrosurgical electrode 128 can be removed from the shaft 126 and replaced with another monopolar electrosurgical electrode 128. In other embodiments, the monopolar electrosurgical electrode 128 can be permanently fixed to the shaft 126 so that the monopolar electrosurgical electrode 128 cannot be replaced with another monopolar electrosurgical electrode 128.

[0063] In FIGS. 3 and 4, the shaft 126 includes a conductive portion 126C and an insulating portion 126D. As described above, the monopolar electrosurgical electrode 128 can extend from the conductive portion 126C of the shaft 126. The insulating portion 126D of the shaft 126 can be a sleeve structure that covers the boundary between the monopolar electrosurgical electrode 128 and the conductive portion 126C of the shaft 126. In this configuration, the insulating portion 126D can help suppress arc discharge and / or supply electrosurgical energy to the monopolar electrosurgical electrode 128. Further, the shaft 126 can include a layer 126E of an insulating material (e.g., a heat-shrinkable material) that covers the remaining portion of the conductive portion 126C of the shaft 126 (e.g., the portion not covered by the insulating portion 126D of the shaft 126) to help suppress arc discharge and / or supply electrosurgical energy to the monopolar electrosurgical electrode 128.

[0064] As described above, the printed circuit board 132 provides at least a part of an electrical circuit for supplying electrosurgical energy from the power cord 122 to the monopolar electrosurgical electrode 128 by being electrically coupled to the shaft 126. As shown in FIG. 4, the printed circuit board 132 includes a first end 132A within the internal cavity 252 of the handle 124, a second end 132B within the internal bore 254 of the shaft 126, and a transmission portion extending between the first end 132A and the second end 132B of the printed circuit board 132.

[0065] The first end 132A of the printed circuit board 132 can be fixedly coupled to the handle 124 so as not to move axially and / or rotationally with respect to the handle 124. In FIG. 4, the proximal portion of the printed circuit board 132 (e.g., the portion of the printed circuit board 132 closer to the first end 132A than the second end 132B) includes the switch 138 (shown in FIG. 1) and is fixedly coupled to the handle 124 adjacent to the user input device 130. The proximal portion of the printed circuit board 132 will be described in more detail below with respect to the examples shown in FIGS. 7A and 7B.

[0066] The second end 132B of the printed circuit board 132 can be fixedly coupled to at least one component within the internal bore 254 of the shaft 126. For example, in FIG. 3, the second end 132B of the printed circuit board 132 includes an LED PCB that is fixedly coupled to the heat sink 458. Thereby, the printed circuit board 132 can also supply electrical energy from the DC power source 144 to the light source 140. In this example, the light source 140 is configured to move axially with the shaft 126 relative to the handle 124, although the shaft 126 is rotatable relative to the handle 124 while the light source 140 maintains a fixed rotational orientation relative to the handle 124.

[0067] In this configuration, the transmission portion of the printed circuit board 132 can have a length greater than the distance between the first end 132A and the second end 132B of the printed circuit board 132 when the shaft 126 is in the furthest position (e.g., fully extended position) relative to the handle 124. When the shaft 126 is in a position proximal to the furthest position relative to the handle, slack in the transmission portion can accumulate within the internal bore 254 of the shaft 126 and / or the internal cavity 252 of the handle 124. For example, as the shaft 126 moves proximally and / or distally relative to the handle 124, the printed circuit board 132 can be a flexible printed circuit board such that the transmission portion curves, bends, and / or folds to occupy the open space within the internal bore 254 of the shaft 126 and / or the internal cavity 252 of the handle 124. Also, for example, the transmission portion can assume a twisted and / or helical state within the open space in response to rotation of the shaft 126 relative to the handle 124.

[0068] As described above, the electrosurgical tool 112 may include one or more components that can help maintain an electrical connection between the printed circuit board 132 and the inner surface of the shaft 126 (and thus the monopolar electrosurgical electrode 128). In FIGS. 3 and 4, the distal portion of the printed circuit board 132 (e.g., the portion of the transmission portion within the inner bore 254 that is distal to the proximal portion of the printed circuit board 132) and the inner surface of the shaft 126 are maintained in electrical communication at least in part by a heat sink 458 within the inner bore 254 of the shaft 126. The heat sink 458 can assist in the transfer of heat from the light source 140 and, in cooperation with one or more additional components, can provide a fixed point that can electrically couple the printed circuit board 132 to the shaft 126. FIGS. 5 and 6 illustrate embodiments in which the heat sink 458 aids in the electrical connection of the printed circuit board 132 to the inner surface of the shaft 126 according to some examples. However, in other examples, the concepts illustrated and described with respect to FIGS. 5 and 6 can be extended to embodiments that include an alternative fixed structure within the inner bore 254 of the shaft 256 instead of omitting the heat sink 458.

[0069] FIG. 5 is a partial cross-sectional view of the shaft 126 along line 360 of FIG. 3 according to one example. In FIG. 5, the shaft 126 includes an inner surface 526A and an outer surface 526B. At least the inner surface 526A is formed of one or more conductive materials. In some examples, the outer surface 526B and / or the wall of the shaft 126 extending between the inner surface 526A and the outer surface 526B may also be formed of the one or more conductive materials.

[0070] As shown in FIG. 5, the heat sink 458 is located within the internal bore 254 of the shaft 126, and the printed circuit board 132 is located between the heat sink 458 and the shaft 126. Also, as shown in FIG. 5, the electrosurgical tool 12 comprises an electrical brush 562 that electrically couples the printed circuit board 132 to the inner surface 526A of the shaft 126. For example, the electrical brush 562 can be located between the printed circuit board 132 and the inner surface 526A of the shaft 126. Further, the electrical brush 562 can include a conductive material (e.g., a metal such as copper) so as to electrically couple the conductive contact 564 of the printed circuit board 132 to the inner surface 526A of the shaft 126.

[0071] In all axial positions and / or rotational orientations of the shaft 126 relative to the handle 124, the heat sink 458, the printed circuit board 132, the electrical brush 562, and the inner surface 526A can have respective sizes and shapes such that the printed circuit board 132 can be in electrical communication with the inner surface 526A of the shaft 126 via the electrical brush 562. For example, the electrical brush 562 and the heat sink 458 can have respective sizes and shapes such that the printed circuit board 132 is pushed toward the heat sink 458 by the electrical brush 562 to maintain the electrical connection between the conductive contact 564 of the printed circuit board 132 and the electrical brush 562. For example, the heat sink 458, the printed circuit board 132, and the electrical brush 562 can be configured such that the electrical brush 562 secures the printed circuit board 132 to the heat sink 458. In FIG. 5, the electrical brush 562 extends around at least half of the outer circumference of the heat sink 458 and can serve to maintain electrical communication with the conductive contact 564 of the printed circuit board 132.

[0072] Also, as shown in FIG. 5, the electrosurgical tool 112 may include an attachment member 566 that couples the electric brush 562, the printed circuit board 132, and the heat sink 458 to each other. For example, the attachment member 566 can extend around the electric brush 562, the printed circuit board 132, and the heat sink 458 and apply a radially inward force thereto. This can help improve the contact between the conductive contact 564 of the printed circuit board 132 and the electric brush 562 and / or fix the position of the electric brush 562 relative to the heat sink 458 and the printed circuit board 132.

[0073] In one example, the attachment member 566 can be a band formed of a heat-shrinkable material. In this example, the process for constructing the electrosurgical tool 112 can include (i) arranging the attachment member 566 around an assembly of the heat sink 458, the printed circuit board 132, and the electric brush 562, and (ii) applying heat to the attachment member 566 to shrink the attachment member 566 around the assembly and apply a radially inward force to the assembly. As another example, the attachment member 566 can include at least one component selected from the group consisting of Kapton® tape, an O-ring, and an adhesive. Also, in other exemplary embodiments, the attachment member 566 can be omitted.

[0074] In some examples, the heat sink 458 can include a recess 568 that extends around at least a portion of the outer periphery of the heat sink 458, and at least a portion of the printed circuit board 132 can be located in the recess 568 of the heat sink 458. For example, in FIG. 5, the conductive contact 564 is located in the recess 568 of the heat sink 458. The recess 568 can help prevent the electric brush 562 from moving axially relative to the printed circuit board 132, the heat sink 458, and / or the shaft 126. Also, the recess 568 can help provide additional space for the electric brush 562 within the inner bore 254 of the shaft 126.

[0075] To electrically couple the printed circuit board 132 to the shaft 126, (i) at least a portion of the electrical brush 562 is in electrical communication with the conductive contact 564 of the printed circuit board 132, and (ii) at least a portion of the electrical brush 562 is in electrical communication with the inner surface 526A of the shaft 126. As an example, in FIG. 5, the electrical brush 562 includes a distal end 570, a proximal end 572, and a central portion 574 between the distal end 570 and the proximal end 572. The central portion 574 engages the conductive contact 564, and the distal end 570 and the proximal end 572 may engage the inner surface 526A of the shaft 126.

[0076] In some examples, the central portion 574 may have a shape corresponding to the shape of the conductive contact 564 of the printed circuit board 132 (e.g., in the recess 568 of the heat sink 458). In one example, at least a portion of the recess 568 may define a substantially flat surface for engaging the printed circuit board 132. Also, the conductive contact 564 and a portion of the electrical brush 562 that engages the conductive contact 564 may have a substantially flat surface. This can help to relatively uniformize the contact between the conductive contact 564 and the electrical brush 562. However, in other examples, the portion of the recess 568 that engages the printed circuit board 132 at the conductive contact 564, the conductive contact 564, and / or the electrical brush 562 may have another shape (e.g., a curved shape).

[0077] As shown in FIG. 5, in some examples, the distal end 570 of the electrical brush 562 and the proximal end 572 of the electrical brush 562 may extend radially outward from the central portion 574 and directly contact the inner surface 526A of the shaft 126. Also, the distal end 570 can extend distally from the central portion 574, and the proximal end 572 can extend proximally from the central portion 574. In this configuration, the electrical brush 562 may have a flexibility suitable for receiving the force applied to the electrical brush 562 by (i) the shaft 126 on one side and (ii) the heat sink 458 and the printed circuit board 132 on the other side. Additionally or alternatively, this configuration can help to reduce friction when the shaft 126 rotates relative to the electrical brush 562.

[0078] In an example, the electric brush 562 can extend around at least a portion of the outer periphery of the inner surface 526A of the shaft 126 (for example, in a dimension perpendicular to the longitudinal axis 350 shown in FIG. 3). For example, the electric brush 562 can extend around at least half of the outer periphery of the inner surface 526A of the shaft 126 and / or around the entire periphery of the inner surface 526A of the shaft 126. Thereby, at one or more positions around the outer periphery of the inner surface 526A of the shaft 126, it is beneficial because the electric brush 562 can electrically couple the conductive contact 564 of the printed circuit board 132 to the shaft 126.

[0079] In some examples, at least a portion of the distal end 570 and at least a portion of the proximal end 572 of the electric brush 562 can have a shape that conforms to the shape of the inner surface 562A of the inner surface 26A of the shaft 126 (for example, at least a portion of the distal end 570 and / or the proximal end 572 can have a curved shape that conforms to the curved contour of the inner surface 526A). This can help increase the degree of contact between the electric brush 562 and the shaft 126. In other examples, the distal end 570 and / or the proximal end 572 can have a shape different from the shape of the inner surface 526A as long as the electric brush 562 is in electrical communication with the inner surface 526A of the shaft 126 at one or more positions on the inner surface 526A.

[0080] As described above, the distal end 570 and / or the proximal end 572 of the electric brush 562 can define the outer surface of the electric brush 562 for engaging the inner surface 526A of the shaft 126. On the other hand, the central portion 574 of the electric brush 562 can define the inner surface of the electric brush 562 for engaging the conductive contact 564 of the printed circuit board 132. However, in other examples, the electric brush 562 can have different configurations. For example, in another example, (i) at least one of the distal end 570, the proximal end 572, and the central portion 574 defines the outer surface of the electric brush 562, and (ii) at least one of the distal end 570, the proximal end 572, and the central portion 574 can define the inner surface of the electric brush 562.

[0081] Referring to FIG. 6, another exemplary embodiment is shown in which heat sink 458 aids in the electrical coupling of printed circuit board 132 to the inner surface of shaft 126. Also, FIG. 6 is a partial cross-sectional view of shaft 126 through line 360 of FIG. 3 according to another example. In FIG. 6, shaft 126 includes an inner surface 626A and an outer surface 626B. At least the inner surface 626A is formed of one or more conductive materials. In some examples, the outer surface 626B and / or the walls of shaft 126 extending between the inner surface 626A and the outer surface 626B may also be formed of the one or more conductive materials.

[0082] In FIG. 6, electrosurgical tool 112 includes a biasing member 676 that applies a force to printed circuit board 132 to press conductive contact 564 of printed circuit board 132 into electrical contact with the inner surface 626A of shaft 126. For example, in FIG. 6, a first portion of biasing member 676 contacts printed circuit board 132, and a second portion of biasing member 676 contacts heat sink 458 such that biasing member 676 is positioned between heat sink 458 and printed circuit board 132 to radially outwardly press conductive contact 564 of printed circuit board 132 toward the inner surface 526A of shaft 126.

[0083] In an example, biasing member 676 may have a size and / or shape relative to the size and / or shape of heat sink 458, printed circuit board 132, and shaft 126 such that biasing member 676 presses conductive contact 564 against the inner surface 526A of shaft 126 with sufficient force to maintain electrical communication while shaft 126 rotates relative to handle 124 and / or printed circuit board 132.

[0084] In some examples, the biasing member 676 may include an elastomeric material. Thereby, the biasing member 676 may be easily assembled by compression and / or expansion while maintaining contact within the tolerance of the shaft 126. Additionally or alternatively, forming the biasing member 676 from an elastomeric material may help prevent the entry of fluid. In one example, the biasing member 676 may include an O-ring.

[0085] In some examples, the biasing member 676 extends around the outer periphery of the heat sink 458 and can provide a gasket that prevents the entry of fluid in the space between the inner surface 626A of the shaft 126 and the heat sink 458. For example, at the axial position of the biasing member 676 along the longitudinal axis 350, the space between the inner surface 626A of the shaft 126 and the heat sink 458 may be substantially occupied by (i) the combination of the printed circuit board 132 and the biasing member 676 along a first outer periphery of the space, and (ii) the biasing member 676 along a second outer periphery of the space. In an example where the biasing member 676 provides a gasket, the biasing member 676 can prevent foreign objects (e.g., fluid and / or debris) from moving proximally along the shaft 126 and entering the internal cavity 252 of the handle 124 (e.g., outside these when the smoke exhaust channels 148 and the smoke exhaust chamber 152 are included). This can help reduce contact of such foreign objects with the electrical components (e.g., the proximal portion of the printed circuit board 132) within the handle 124.

[0086] In some examples, the heat sink 458 can include a recess 668 that extends around at least a portion of the outer periphery of the heat sink 458, and the biasing member 676 can be positioned within the recess 668. The recess 668 can serve to hold the biasing member 676 in an axial position fixed with respect to the heat sink 458 (e.g., along the longitudinal axis 350). Thus, the recess 668 can help to prevent the biasing member 676 from moving axially with respect to the printed circuit board 132, the heat sink 458, and / or the shaft 126. Also, the recess 668 can serve to provide additional space for the biasing member 676 within the inner bore 254 of the shaft 126.

[0087] Also, in some examples, the recess 668 can extend around the entire circumference of the heat sink 458. For example, in an example where the biasing member 676 extends around the entire circumference of the heat sink 458, the recess 668 can serve to hold the biasing member 676 in the fixed axial position by extending around the entire circumference of the heat sink 458. However, in other examples, the recess 668 can extend less than the entire circumference of the heat sink 458. This can be useful for cost reduction, for example, by improving the assembly process and / or reducing the cost of machining.

[0088] Referring to FIGS. 7A and 7B, one embodiment of a printed circuit board 132 according to an example is shown. In particular, FIG. 7A is a first side view of the printed circuit board 132, and FIG. 7B is a second side view of the printed circuit board 132 opposite the first side view shown in FIG. 7A.

[0089] In FIGS. 7A and 7B, the printed circuit board 132 is a flexible printed circuit board. For example, the printed circuit board 132 can include a plurality of electrical circuits on a flexible substrate. For example, in one embodiment, the printed circuit board 132 can include one or more conductive layers of conductive material (e.g., copper) traces on a polyimide dielectric layer.

[0090] As shown in FIGS. 7A and 7B, the printed circuit board 132 has a first end 132A, a second end 132B, and a transmission portion 777 extending between the first end 132A and the second end 132B. As described above, the first end 132A of the printed circuit board 132 can be fixedly coupled to the handle 124 in the internal cavity 252 of the handle 124 so as not to move axially and / or rotationally with respect to the handle 124. For example, in FIG. 7A, the proximal portion 732A of the printed circuit board 132 includes a switch 138 and is fixedly coupled to the handle 124 adjacent to the user input device 130. The switch 138 is operable by a user input device 130 (e.g., a plurality of buttons 330A, 330B shown in FIG. 3) on the handle 124 to control the electrosurgical energy supplied to the monopolar electrosurgical electrode 128.

[0091] As shown in FIG. 7B, the printed circuit board 132 may include a first PCB reinforcement 778 coupled to the proximal portion 732A on the second side of the printed circuit board 132 to assist in the fixed coupling of the proximal portion 732A to the handle 124. The first PCB reinforcement 778 can be formed of any material suitable for improving the stability and / or rigidity of the proximal portion 732A of the printed circuit board 132. In one example, the first PCB reinforcement 778 may include a heat transfer material such as aluminum. This can also help in the transfer of heat from the proximal portion 732A of the printed circuit board 132.

[0092] Moreover, the proximal portion 732A of the printed circuit board 132 may include a plurality of power cord contacts 780 for electrically coupling to the respective conductors of the power cord 122 (shown in FIG. 1). In FIG. 7A, the printed circuit board 132 includes three power cord contacts 780 configured to couple to three conductors of the power cord 122 that enable the supply of electrosurgical energy from the electrosurgical generator 110 to the printed circuit board 132. In one example where a DC power source 144 is disposed along the power cord 122 and / or in the plug of the power cord 122, the printed circuit board 132 may include two power cord contacts 780 configured to couple to two conductors of the power cord 122 that supply DC power from the DC power source 144 to the light source 140.

[0093] As described above, the second end 132B of the printed circuit board 132 may be fixedly coupled to at least one component (e.g., heat sink 458) within the inner bore 254 of the shaft 126. In the examples shown in FIGS. 3, 4, 7A, and 7B, the second end 132B of the printed circuit board 132 includes the light source 140 and is fixedly coupled between the heat sink 458 and the optical structure 142. As shown in FIG. 7B, the printed circuit board 132 may include a second PCB reinforcement 782 coupled to the second end 132B on the second side of the printed circuit board 132 to assist in the fixed coupling of the second end 132B between the heat sink 458 and the optical structure 142. The second PCB reinforcement 782 may be formed of any material suitable for improving the stability and / or rigidity of the second end 132B and / or the light source 140. In one example, the second PCB reinforcement 782 may include a heat transfer material such as aluminum, for example. This may also assist in the transfer of heat from the light source 140 to the heat sink 548 side. The coupling of the second end 132B to the heat sink 548 and / or the optical structure 142 will be described in more detail below with respect to FIGS. 12 and 13.

[0094] The transmission part 777 extends between the first end 132A and the second end 132B. As shown in FIGS. 4, 7A, and 7B, the printed circuit board 132 has an elongated axial dimension extending between the first end 132A and the second end 132B, and this axial dimension can be parallel to the longitudinal axis 250 of the shaft 126 (shown in FIG. 3). In this configuration, the transmission part 777 of the printed circuit board 132 can have a length greater than the distance between the first end 132A and the second end 132B of the printed circuit board 132 when the shaft 126 is in the farthest position (e.g., fully extended position) with respect to the handle 124. When the shaft 126 is in a position proximal to the farthest position with respect to the handle, the slack of the transmission part can accumulate in the inner bore 254 of the shaft 126 and / or the inner cavity 252 of the handle 124.

[0095] For example, in FIGS. 4 to 6, the heat sink 458 does not extend to the proximal end of the inner bore 254 so that a space is provided in the inner bore 254 between the heat sink 458 and the proximal end of the shaft 126. Therefore, this space can receive the slack of the printed circuit board 132, and the axial movement of the shaft 126 and the second end 132B of the printed circuit board 132 with respect to the first end 132A of the printed circuit board 132 is promoted.

[0096] As shown in FIG. 7A, the printed circuit board 132 includes conductive contacts 564 for electrically coupling the printed circuit board 132 to the inner surfaces 526A, 626A of the shaft 126, and these conductive contacts 564 are located between the first end 132A and the second end 132B of the printed circuit board 132. The conductive contacts 564 can include a part of the conductive wiring of the printed circuit board 132 that is exposed without being covered by a dielectric material. Therefore, the exposed conductive material of the conductive contacts 564 can be electrically coupled to the inner surfaces 526A, 626A of the shaft 126 as described above. As an example, the conductive contacts 564 can include copper.

[0097] As shown in FIG. 7A, the width W of the printed circuit board 132 at the conductive contacts 5641 is the width W of the printed circuit board 132 in the first portion of the printed circuit board 132 located proximal to the conductive contact 564 and / or in the second portion of the printed circuit board 132 located distal to the conductive contact 564 2 can be made larger than. In this configuration, by expanding the conductive contact 564 with respect to one or more portions of the transmission portion 777, the surface area of electrical contact with the inner surfaces 526A, 626A of the shaft 126 can be increased. On the other hand, the proximal portion and / or the distal portion of the transmission portion 777 may have a relatively small size in consideration of the space constraints due to the accumulation of slack of the transmission portion 777 at one or more axial positions of the shaft 126 with respect to the handle 124.

[0098] In this configuration, the first end 132A of the printed circuit board 132 can receive electrosurgical energy from the power cord 122 (shown in FIG. 1), the transmission portion 777 can supply electrosurgical energy from the first end 132A to the conductive contact 564, the conductive contact 564 can supply electrosurgical energy to the inner surfaces 526A, 626A of the shaft 126, and the shaft 126 can supply electrosurgical energy to the monopolar electrosurgical electrode 128. In an example, the printed circuit board 132 can supply electrosurgical energy in this way at all axial positions and / or all rotational orientations of the shaft 126 with respect to the handle 124. Also, in an example including the light source 140, the first end 132A of the printed circuit board 132 can receive DC power from the power cord 122 (shown in FIG. 1), and the transmission portion 777 can supply DC power from the first end 132A to the light source 140 at the second end 132B.

[0099] As described above, the printed circuit board 132 may include a first PCB reinforcement 778 at the proximal portion 732A of the printed circuit board and / or a second PCB reinforcement 782 at the second end portion 132B. In an example, the PCB reinforcement may be omitted at at least a part or all of the transmission portion 777 of the printed circuit board. Thereby, since the transmission portion 777 is more flexible than the second end portion 132B and / or the proximal portion 732A, it can be curved and / or bent when receiving the movement of the shaft 126 with respect to the handle 124.

[0100] FIG. 8 shows another embodiment of the printed circuit board 132 according to another example. In particular, FIG. 8 shows a second end portion 132B, a light source 140, and a conductive contact 564 as the distal portion of the printed circuit board 132 according to this example. As shown in FIG. 8, the transmission portion 777 can have a rectangular shape, and the conductive contact 564 can have a triangular shape. The triangular shape of the conductive contact 564 can help increase the surface area of electrical contact.

[0101] Referring to FIG. 9, an enlarged view of a cross-section of the distal end 126B of the shaft 126 passing through the longitudinal axis 350 and the monopolar electrosurgical electrode 128 according to an example is shown. As shown in FIG. 9, the distal portion 128A of the monopolar electrosurgical electrode 128 may define an active end configured to apply electrosurgical energy to tissue. The proximal portion 128B of the monopolar electrosurgical electrode 128 may include a first leg portion 984A extending from the distal end 126B of the shaft 126 and a second leg portion 984B extending from the distal end of the conductive portion 126C of the shaft 126.

[0102] In FIG. 16, the first leg 984A and the second leg 984B are arranged diametrically opposite to each other around the outer periphery of the distal end 126B of the shaft 126. Also, the proximal facing surface 985 of the proximal portion 128B of the monopolar electrosurgical electrode 128 tapers distally towards the central axis of the shaft 126, so that at the most distal end of the shaft 126, a gap 986 can be defined between the proximal facing surface 985 and the plane 987. The gap 986 can help improve the air flow and suction at the distal end 126B of the shaft 126.

[0103] Also, as shown in FIG. 9, the sleeve structure of the insulating portion 126D can extend around the optical structure 142. The sleeve structure may be an optically opaque material. At least a part of each distal transmissive surface of the optical structure 142 can extend to a position distal to the most distal end of the sleeve structure of the insulating portion 126D in order to increase the intensity of the light emitted from the optical structure 142.

[0104] As described above, the monopolar electrosurgical electrode 128 can include a proximal portion 128B extending from the distal end of the shaft 126 and a distal portion 128A including an operative end configured to apply electrosurgical energy to tissue. In FIGS. 3, 4, and 9, the central axis of the distal portion 128A of the monopolar electrosurgical electrode 128 and the central axis of the smoke exhaust channel 148 are collinear. In this configuration, the smoke exhaust channel 148 can have a substantially constant size around the outer periphery of the monopolar electrosurgical electrode 128. This can help provide relatively consistent suction at each point around the monopolar electrosurgical electrode 128. However, in other examples, the central axes of the monopolar electrosurgical electrode 128 and the shaft 126 can be offset and parallel to each other.

[0105] Also, as shown in FIGS. 3, 4, and 9, the smoke exhaust channel 148 can define a space with no other structure between the proximal end 148A and the distal end 148B of the smoke exhaust channel 148. This enables more efficient use of the relatively limited size of the internal bore 254 to enhance suction through the smoke exhaust channel 148 as compared to other embodiments where the monopolar electrosurgical electrode 128 and / or other components are disposed in the smoke exhaust channel 148.

[0106] Also, as described above, according to some examples, the smoke exhaust channel 148 can be rotationally fixed relative to the handle 124 such that the shaft 126 and the monopolar electrosurgical electrode 128 are rotatable relative to the smoke exhaust channel 148. FIGS. 10 and 11 show the smoke exhaust channel 148 and the shaft 126 according to one example. As shown in FIGS. 4, 10, and 11, at least a portion of the smoke exhaust channel 148 can have a non-circular shape to prevent rotation of the smoke exhaust channel 148 relative to the handle 124 while the shaft 126 and the monopolar electrosurgical electrode 128 rotate relative to the handle 124.

[0107] For example, the proximal end 148A of the smoke exhaust channel 148 can include a non-rotating fit configured to engage a structure of a corresponding shape of the handle 124, and the non-rotating fit can have a non-circular cross-sectional shape. For example, in FIGS. 4 and 10, the proximal end 148A of the smoke exhaust channel 148 has a hexagonal mechanism that engages a hexagonal socket formed in the inner surface of the handle 124 to prevent rotation between the smoke exhaust channel 148 and the handle 124. Also, as shown in FIG. 11, a gap can be defined between the shaft 126 and the smoke exhaust channel 148 to allow rotation of the shaft 126 relative to the smoke exhaust channel 148.

[0108] As shown in FIG. 10, the non-rotating fitting at the proximal end 148A of the smoke exhaust channel 148 may include a through bore 1088 having a cross-sectional area smaller than the cross-sectional area of the body 148C of the smoke exhaust channel 148 located proximal to the non-rotating fitting. Since the size of the through bore 1088 is relatively small, it can assist in guiding the smoke emerging from the proximal end 148A of the smoke exhaust channel 148 into a relatively small spatial volume. This is beneficial because it can help suppress or prevent the exposure of the electrical components within the inner bore 125 of the handle 124 to the smoke.

[0109] FIG. 12 is a partially exploded view of an assembly of a printed circuit board 132, a light source 140, an optical structure 142, a heat sink 584, and a smoke exhaust channel 148 according to an example. As shown in FIGS. 4, 9, and 12, the electrosurgical tool 112 may include the light source 140 and the optical structure 142 within the shaft 126 of the housing 123. As described above, the light source 140 is configured to emit light into the optical structure 142, and the optical structure 142 is configured to transmit light distally from the light source 140 and emit light from the distal end 126B of the shaft 126.

[0110] In FIG. 12, the light source 140 is located at the second end 132B of the printed circuit board 132. The transmission portion 777 may extend along the smoke exhaust channel 148 and the heat sink 458. In one example, the second end 132B of the printed circuit board 132 may be pressed against the proximal end of the heat sink 458 to connect (mate) the heat sink 458, the second end 132B (e.g., including the second PCB reinforcement 782 and the light source 140), and the optical structure 142 to the first leg 984A and / or the second leg 984B of the monopolar electrosurgical electrode 128 by a washer (e.g., a toothed washer). For example, FIG. 13 shows the connection between the first leg 984A and the second leg 984B of the monopolar electrosurgical electrode 128. In this configuration, the second end 132B may be compressed by the heat sink 458 and the optical structure 142 and held in place.

[0111] FIG. 13 shows an assembly of an optical structure 142 and a monopolar electrosurgical electrode 128 according to an example. As shown in FIG. 13, the monopolar electrosurgical electrode 128 has a longitudinal axis 1390 that extends between a proximal end of the electrosurgical electrode 128 and a distal end of the electrosurgical electrode 128. The light source 140 can be circumferentially arranged around the longitudinal axis 1390 of the monopolar electrosurgical electrode 128. Arranging the light source 140 around the monopolar electrosurgical electrode 128 can help disperse light over the entire circumference of the monopolar electrosurgical electrode 128, thus reducing dark areas (shadows) and helping to improve the uniformity of illumination in all rotational alignment positions of the monopolar electrosurgical electrode 128 with respect to the handle 124 and / or the electrosurgical tool 112 with respect to the target tissue.

[0112] Also, the smoke exhaust channel 148 can extend through an opening 1391 in the optical structure 142 and a PCB opening 1392 in the second end 132B of the printed circuit board 132. This helps to position the smoke exhaust channel 148 at the center of the shaft 126 (for example, the central axis of the smoke exhaust channel 148 and the central axis of the shaft 126 can be collinear), and the suction at the surgical site can be enhanced. In this configuration, the electrosurgical tool 112 can provide illumination and suction around the outer circumference of the monopolar electrosurgical electrode 128. Further, in this configuration, by integrating the optical structure 142, the quality of illumination can be improved, the size of the distal end of the electrosurgical tool can be reduced, and the line of sight to the surgical site can be improved.

[0113] Referring again to FIG. 3, the user input device 130 may include a first button 330A and a second button 330B on the outer surface of the handle 124. In one embodiment, activation of the first button 330A can operate the electrosurgical tool 112 in a cutting operation mode, and activation of the second button 330B can operate the electrosurgical tool 112 in a coagulation operation mode. In this example, a third button (not shown) can be provided on the plug of the power cord 122 and / or on the electrosurgical generator 110, and activation of this third button can operate the light source 140 (i.e., cause the light source 140 to emit light or stop emitting light). As described above, the user input device 130 can have a different configuration in other examples. For example, the electrosurgical tool 112 can operate in fewer operation modes, more operation modes, and / or different types of operation modes in other examples (such as the exemplary operation modes described above). Also, for example, at least one user input device 130 can include, in addition to or as an alternative to the above, the user interface 116 of the electrosurgical generator 110 and / or another external device (such as a foot switch) for operating the electrosurgical tool 112 in one or more operation modes. Also, for example, the user input device 130 on the handle 124 can include a third button for operating the light source 140.

[0114] The electrosurgical tool 112 shown in FIGS. 3-13 includes a smoke exhaust channel 148, a light source 140, and an optical structure 142, but in other embodiments, one or more of these components can be omitted.

[0115] Figures 14 to 21 show additional components of the electrosurgical tool 112 according to an additional example or an alternative example. In particular, FIG. 14 is a side view of the electrosurgical tool 112 with the first part of the handle 124 omitted for explanation, FIG. 15 is a first perspective view of the electrosurgical tool 112 with the second part of the handle 124 (opposite to the first part of the handle 124) omitted for explanation, FIG. 16 is a second perspective view of the electrosurgical tool 112 with the second part of the handle 124 omitted for explanation, FIG. 17 shows the electrosurgical tool 112 with both the first part and the second part of the handle 124 omitted for explanation, FIG. 18 is an exploded view of the stopper assembly 1793 of the electrosurgical tool 112, FIG. 19 shows the shaft stopper 1794 of the stopper assembly 1793 according to an example, FIG. 20 is a partial cross-sectional view of the connection between the shaft stopper 1794 and the shaft 126, and FIG. 21 shows the rotation nut 1795 according to an example.

[0116] As shown in FIGS. 15 and 16, a part of the printed circuit board 132 can be fixedly coupled to the inner wall 1524 of the handle 124. The part of the printed circuit board 132 coupled to the inner wall 1524 of the handle 124 can be the part of the printed circuit board 132 located outside the inner bore 254 of the shaft 126. The fact that the printed circuit board 132 is fixedly coupled to the inner wall 1524 of the handle 124 can help to suppress or prevent the entanglement and / or bunching of the printed circuit board 132 when the shaft 126 moves longitudinally with respect to the handle 124.

[0117] As an example, FIG. 15 shows the zone 1501 of the inner wall 1524 of the handle 124 to which the printed circuit board 132 can be fixedly coupled. The zone 1501 can be elongated along the longitudinal axis 350 (shown in FIG. 3). This helps to increase the surface area of the connection between the printed circuit board 132 and the inner wall 1524 of the handle 124, and can enhance the strength of the connection between the printed circuit board 132 and the inner wall 1524 of the handle 124.

[0118] In some examples, zone 1501 may have a surface roughness greater than that of other portions of the inner wall 1524 of the handle 124 surrounding the zone 1501. For example, in one embodiment, the manufacturing process may include roughening the inner wall 1524 in zone 1501 (e.g., by sanding, thermal energy, chemical etching, and / or spraying) and not roughening other portions of the inner wall 1524. In another embodiment, the manufacturing process may include reducing the roughness of other portions of the inner wall 1524 and maintaining the surface roughness of zone 1501. By increasing the surface roughness of zone 1501 relative to other portions of the inner wall 1524, zone 1501 can enhance the coupling between the printed circuit board 132 and the handle 124 and / or provide a tactile indication of a suitable coupling position to the assembler during the manufacturing process.

[0119] In the examples shown in FIGS. 14-20, the electrosurgical tool 112 is configured to define a limited range of rotation between the shaft 126 and the handle 124. Limiting the range of rotation between the shaft 126 and the handle 124 can help to suppress excessive stress on the printed circuit board 132 resulting from over-rotation of the shaft 126 relative to the handle 124. As described above, in one embodiment, the monopolar electrosurgical electrode 128 may be rotatable more than 360° relative to the handle 124. This can improve usability by allowing the operator to freely rotate the monopolar electrosurgical electrode 128 without limitation. However, in other embodiments, the monopolar electrosurgical electrode 128 may be rotatable by less than 360° (e.g., 180° of rotation or 360° of rotation). Even in this case, the operator can still achieve the desired rotational configuration, for example, by rotating in a first direction and then reverse-rotating in a second direction after reaching a stopper that limits further rotation.

[0120] In the examples shown in FIGS. 14 to 20, the electrosurgical tool 112 includes a stopper assembly 1793 configured to limit the rotational movement range between the shaft 126 and the handle 124 to a predetermined rotational movement range. For example, in FIGS. 14 to 20, the stopper assembly 1793 is configured to provide a rotational movement range of approximately 400° to each of the shaft 126 and the handle 124. However, as described above, the stopper assembly 1793 can be configured such that the shaft 126 and the handle 124 can have different rotational movement ranges relative to each other.

[0121] As shown in FIGS. 17 and 18, the stopper assembly 1793 includes a shaft 126, a shaft stopper 1794, and a rotary nut 1795. In this example, the shaft stopper 1794 is fixedly coupled to the proximal portion of the shaft 126, and the rotary nut 1795 is rotatably coupled to the shaft stopper 1794. As shown in FIGS. 14 to 16, although the rotary nut 1795 is fixed in the rotational direction with respect to the handle 124, it is axially movable with respect to the handle 124. As will be described in more detail below, the rotational coupling between the shaft stopper 1794 and the rotary nut 1795 defines the rotational movement range of the shaft 126 with respect to the handle 124.

[0122] As shown in FIG. 19, the shaft stopper 1794 includes a through bore 1994A extending between the proximal end 1994B and the distal end 1994C of the shaft stopper 1794, a shaft coupling mechanism 1994D, and a male thread 1994E. As shown in FIGS. 17 and 20, the through bore 1994A is configured to receive the proximal portion of the shaft 126 such that the shaft stopper 1794 surrounds the proximal portion of the shaft 126.

[0123] The shaft coupling mechanism 1994D is configured to fixedly couple the shaft stopper 1794 to the proximal portion of the shaft 126. For example, in FIG. 19, the shaft coupling mechanism 1994D includes a plurality of tabs configured to engage and couple to a plurality of openings 1896 in the proximal portion of the shaft 126 when the proximal portion of the shaft 126 is received in the through bore 1994A of the shaft stopper 1794. FIG. 18 shows the openings 1896 in the proximal portion of the shaft 126, and FIG. 20 shows the tabs of the shaft coupling mechanism 1994D that fix the shaft stopper 1794 to the shaft 126 in the rotational and axial directions by engaging the openings 1896.

[0124] The shaft stopper 1794 is rotatably coupled to a rotary nut 1795. For example, as shown in FIG. 21, the rotary nut 1795 may include an internal thread 2195A that can threadably engage the external thread 1994E of the shaft stopper 1794. The range of motion between the shaft 126 and the handle 124 corresponds to the range of motion between the shaft stopper 1794 and the rotary nut 1795, which is defined by the external thread 1994E of the shaft stopper 1794 and the internal thread 2195A of the rotary nut 1795. For example, this range of motion may be defined by the length and / or the number of turns of the external thread 1994E and / or the internal thread 2195A.

[0125] Referring to FIG. 21, the rotary nut 1795 may include one or more protrusions 2195B configured to assist in preventing rotation of the rotary nut 1795 relative to the handle 124 and to allow axial movement of the rotary nut 1795A relative to the handle 124. For example, as shown in FIGS. 15 and 16, the handle 124 may include one or more longitudinal slots 1597 configured to receive respective ones of the protrusions 2195B of the rotary nut 1795A. The longitudinal slots 1597 extend longitudinally (e.g., parallel to the longitudinal axis 350 shown in FIG. 3) by a length greater than the length by which the shaft 126 can move axially relative to the handle 124. In this configuration, the engagement between the protrusion 2195B and the longitudinal slot 1597 prevents rotation of the rotary nut 1795 relative to the handle 124 and allows axial movement of the rotary nut 1795 relative to the handle 124.

[0126] In FIGS. 14-21, the handle 124 includes two longitudinal slots 1597 on the upper inner surface 1598 and two longitudinal slots 1597 on the lower inner surface 1698. As shown in FIG. 21, the rotary nut 1795 includes corresponding two protrusions 2195B on the upper outer surface configured to fit with the two longitudinal slots 1597 on the upper inner surface 1598 and corresponding two protrusions 2195B on the lower outer surface configured to fit with the two longitudinal slots 1597 on the lower inner surface 1698. FIGS. 14-16 show the protrusions 2195B within the longitudinal slots 1597 of the handle 124. In this configuration, the rotary nut 1795 (i) moves axially with the shaft 126 (e.g., by the connection between the rotary nut 1795 and the shaft stopper 1794 fixedly coupled to the shaft 126), (ii) rotation relative to the handle 124 is blocked by the engagement between the protrusion 2195B and the longitudinal slot 1597, and (iii) the threaded engagement with the shaft stopper 1794 in a state fixed in the rotational direction relative to the handle 124 limits the rotation of the shaft 126 and the handle 124 to a predetermined rotational movement range.

[0127] In FIGS. 14 to 21, the rotary nut 1795 is C-shaped (for example, the inner surface of the bore of the rotary nut 1795 does not extend over the entire circumference of the bore of the rotary nut 1795). For example, the inner surface and the outer surface of the rotary nut 1795 can extend as an arc around the central axis passing through the bore of the rotary nut 1795 for about 270° to about 350°. In this configuration, the rotary nut 1795 can have opposing ends that define an opening through the side wall of the rotary nut 1795 (for example, between the bore of the rotary nut 1795 and the outside of the bore). This can, for example, assist in assembly. For example, the C-shape of the rotary nut 1795 can increase the size of the opening by bending and / or flexing the rotary nut 1795 such that the shaft stopper 1794 can be inserted through the opening between the ends and into the bore of the rotary nut 1795. After inserting the shaft stopper 1794 through the opening and into the bore of the rotary nut 1795, the size of the rotary nut 1795 can elastically decrease again around the shaft stopper 1794. In some examples, the shaft stopper 1794 can be inserted through the opening of the rotary nut 1795 with the printed circuit board 132 positioned within the through-bore 1994A of the shaft stopper 1794.

[0128] FIG. 46 is a cross-sectional view of an electrosurgical tool 112 passing through a handle 124, a shaft stopper 1794, and a rotary nut 1795, according to another example. The example shown in FIG. 46 is different from the examples shown in FIGS. 14 to 21 and described above in that the protrusions 2195B and the longitudinal slots 1597 for non-rotational engagement between the handle 124 and the rotary nut 1795 have a different configuration from the similar mechanisms shown in FIGS. 17 to 21. For example, as shown in FIG. 46, the protrusions 2195B of the rotary nut 1795 may each have a dovetail shape that is received within a corresponding longitudinal slot 1597 of the handle 124 having a corresponding dovetail shape. In this configuration, as described above with respect to the rotary nut 1795, the engagement between the protrusion 2195B and the longitudinal slot 1597 prevents rotation of the rotary nut 1795 with respect to the handle 124 and allows axial movement of the rotary nut 1795 with respect to the handle 124.

[0129] In FIG. 46, the handle 124 includes one longitudinal slot 1597 on the upper inner surface 1598 and one longitudinal slot 1597 on the lower inner surface 1698. As shown in FIG. 46, the rotary nut 1795 has corresponding dovetail-shaped protrusions 2195B on the upper outer surface that are configured to fit into the dovetail-shaped longitudinal slots 1597 on the upper inner surface 1598, and corresponding dovetail-shaped protrusions 2195B on the lower outer surface that are configured to fit into the dovetail-shaped longitudinal slots 1597 on the lower inner surface 1698. In this configuration, the rotary nut 1795 (i) moves axially with the shaft 126 (e.g., by the connection between the rotary nut 1795 and a shaft stopper 1794 fixedly coupled to the shaft 126), (ii) rotation with respect to the handle 124 is prevented by the engagement between the protrusion 2195B and the longitudinal slot 1597, and (iii) the rotation of the shaft 126 and the handle 124 is limited to a predetermined rotational movement range by a threaded engagement with the shaft stopper 1794 in a state where the rotary nut 1795 is fixed in the rotational direction with respect to the handle 124.

[0130] Referring to FIG. 22, a process 2200 for operating an electrosurgical tool according to an example is shown. As shown in FIG. 22, at block 2210, the process 2200 includes coupling a power cord of the electrosurgical tool to an electrosurgical generator. The electrosurgical tool includes a handle that defines an internal cavity and a shaft that extends distally from the internal cavity of the handle. The shaft defines an internal bore. The electrosurgical tool also includes a printed circuit board disposed within the internal bore of the shaft. The printed circuit board is electrically coupled to the power cord. The shaft is movable relative to the handle and the printed circuit board. The electrosurgical tool further includes an electrosurgical electrode that extends distally from the distal end of the shaft.

[0131] At block 2212, the process 2200 includes using the power cord to supply electrosurgical energy from the electrosurgical generator to the printed circuit board. At block 2214, the process 2200 includes supplying, by the printed circuit board, electrosurgical energy from the power cord to the inner surface of the shaft. At block 2216, the process 2200 further includes conducting electrosurgical energy from the shaft to the electrosurgical electrode.

[0132] FIGS. 23-33 show additional aspects of the process 2200 according to other examples. As shown in FIG. 23, the process 2200 may include, at block 2218, axially moving the shaft relative to the handle while maintaining an electrical connection between the printed circuit board and the inner surface of the shaft, and, in response to axially moving the shaft relative to the handle at block 2218, at block 2220, folding a first portion of the printed circuit board over a second portion of the printed circuit board.

[0133] As shown in FIG. 24, process 2200 may include, at block 2222, rotating the shaft relative to the handle while maintaining an electrical coupling between the printed circuit board and the inner surface of the shaft, and, in response to rotating the shaft relative to the handle at block 2222, at block 2224, coiling the printed circuit board in at least one of an inner bore of the shaft or an inner cavity of the handle.

[0134] As shown in FIG. 25, supplying electrosurgical energy from a power cord to the inner surface of the shaft by the printed circuit board at block 2214 may include, at block 2226, electrically coupling the printed circuit board to the inner surface of the shaft by an electrical brush.

[0135] As shown in FIG. 26, electrically coupling the printed circuit board to the inner surface of the shaft by an electrical brush at block 2226 may include, at block 2228, pressing the printed circuit board between the electrical brush and a heat sink within an inner bore of the shaft.

[0136] Also, as shown in FIG. 27, process 2200 may include, at block 2230, axially holding the electrical brush in a recess extending around at least a portion of an outer periphery of the heat sink.

[0137] Also, as shown in FIG. 28, process 2200 may include, at block 2232, coupling the electrical brush, the printed circuit board, and the heat sink to one another by an attachment member.

[0138] As shown in FIG. 29, supplying electrosurgical energy from a power cord to the inner surface of the shaft by the printed circuit board at block 2214 may include, at block 2234, contacting a conductive contact of the printed circuit board to the inner surface of the shaft by a biasing member.

[0139] As shown in FIG. 30, process 2200 may include, at block 2236, using a biasing member to prevent fluid from entering the space between the inner surface of the shaft and the heat sink.

[0140] Also, as shown in FIG. 31, process 2200 may include, at block 2238, using a printed circuit board to transmit DC power from a DC power source to a light source within the inner bore of the shaft.

[0141] Also, as shown in FIG. 32, process 2200 may include, at block 2240, rotating the shaft with respect to a smoke exhaust channel within the inner bore of the shaft.

[0142] Also, as shown in FIG. 33, process 2200 may include, at block 2242, limiting the rotation of the shaft with respect to the handle to a predetermined rotational movement range by a stopper assembly of the electrosurgical tool.

[0143] Referring to FIG. 34, a process 3400 for manufacturing an electrosurgical tool according to an example is shown. As shown in FIG. 34, at block 3410, process 3400 includes forming a housing that includes a handle defining an internal cavity and a shaft extending distally from the internal cavity of the handle. The shaft defines an inner bore. At block 3412, process 3400 includes disposing a printed circuit board within the inner bore of the shaft. At block 3414, process 3400 includes electrically coupling the printed circuit board to a power cord. The power cord is coupled to an electrosurgical generator and is configured to receive electrosurgical energy from the electrosurgical generator. The shaft is movable with respect to the handle and the printed circuit board. At block 3416, process 3400 includes electrically coupling the printed circuit board to the inner surface of the shaft. At block 3418, process 3400 includes electrically coupling an electrosurgical electrode to the distal end of the shaft. The shaft is configured to conduct electrosurgical energy to the electrosurgical electrode.

[0144] Figures 35 to 45 show additional aspects of process 3400 according to other examples. As shown in Figure 35, process 3400 may include, at block 3420, disposing a heat sink within an inner bore of the shaft. Also, in Figure 35, at block 3412, disposing a printed circuit board within the inner bore of the shaft may include, at block 3422, disposing the printed circuit board between the heat sink and the shaft.

[0145] As shown in Figure 36, at block 3412, disposing a printed circuit board within the inner bore of the shaft may include, at block 3424, disposing at least a portion of the printed circuit board within a recess of the heat sink. The recess may extend around at least a portion of the outer periphery of the heat sink.

[0146] As shown in Figure 37, at block 3416, electrically coupling a printed circuit board to the inner surface of the shaft may include, at block 3426, electrically coupling an electrical brush to the inner surface of the printed circuit board and the shaft.

[0147] Also, as shown in Figure 38, process 3400 may include, at block 3428, disposing an electrical brush around at least half of the outer periphery of the heat sink.

[0148] Also, as shown in Figure 39, process 3400 may include, at block 3430, coupling a mounting member around the electrical brush, the printed circuit board, and the heat sink.

[0149] As shown in Figure 40, at block 3430, coupling a mounting member around the electrical brush, the printed circuit board, and the heat sink may include, at block 3432, applying heat to a heat shrink material of the mounting member.

[0150] As shown in FIG. 41, in block 3416, electrically coupling the printed circuit board to the inner surface of the shaft may include, in block 3434, using a biasing member within a recess extending around at least a portion of the outer periphery of the heat sink to contact the printed circuit board against the inner surface of the shaft.

[0151] Also, as shown in FIG. 42, process 3400 may include, in block 3436, forming conductive contacts on the printed circuit board. The width of the printed circuit board at the conductive contacts can be made greater than the width of the printed circuit board at a first portion of the printed circuit board located proximal to the conductive contacts and at a second portion of the printed circuit board located distal to the conductive contacts.

[0152] Also, as shown in FIG. 43, process 3400 may include, in block 3438, coupling a light source to a second end of the printed circuit board. The printed circuit board can have a first end and a second end, and the printed circuit board can have an elongated axial dimension extending between the first end and the second end, and the axial dimension can be parallel to the longitudinal axis of the shaft.

[0153] Also, as shown in FIG. 44, process 3400 may include, in block 3440, fixedly coupling a portion of the printed circuit board to a zone of the inner wall of the housing.

[0154] Also, as shown in FIG. 45, process 3400 may include, in block 3442, roughening the inner wall in a zone and not roughening other portions of the inner wall surrounding the zone.

[0155] For purposes of illustration and description above, various advantageous configurations have been described, but this description is not intended to be exhaustive or limited to examples of the disclosed forms. Many improvements and variations will be apparent to those skilled in the art. Further, the various advantageous examples may represent different advantages from other advantageous examples. The one or more examples selected were chosen and described in order to explain the principles of the examples, actual use, and to enable others skilled in the art to understand the disclosure with various improvements made to suit the particular uses contemplated.

[0156] Also, features described as optional in the variations of the invention described may be claimed, either independently or in combination with any one or more of the features described herein. Similarly, references to a single element include the possibility that more than one of the same element exists. More specifically, as used in this specification and the appended claims, the singular forms "a", "and", "said", and "the" include plural referents unless the context clearly dictates otherwise. Further, note that the claims may be drafted to exclude optional elements. For this reason, this specification is intended to serve as a precedent for the use of exclusive terms such as "solely", "only", etc. 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 the present application is not limited by this specification, but is to be limited only by the plain meaning of the claim terms employed.

Claims

1. A handle that defines the internal cavity, A power cord connected to an electrosurgical generator and configured to receive electrosurgical energy from the electrosurgical generator, A shaft extending distally from the internal cavity of the handle and defining the internal bore, A printed circuit board located within the internal bore of the shaft, wherein the printed circuit board is electrically coupled to the power cord and configured to conduct the electrosurgical energy from the power cord to the inner surface of the shaft, and the shaft is at least one of the following: (i) rotatable with respect to the handle and the printed circuit board, or (ii) movable in a nested manner with respect to the handle and the printed circuit board. An electrosurgical electrode extending distally from the distal end of the shaft, wherein the shaft is configured to conduct the electrosurgical energy to the electrosurgical electrode, and An electrosurgical tool equipped with [specific features / equipment].

2. The shaft is further provided with a heat sink inside the internal bore, The electrosurgical tool according to claim 1, wherein the printed circuit board is located between the heat sink and the shaft.

3. The heat sink includes a recess that extends around at least a portion of the outer circumference of the heat sink, The electrosurgical tool according to claim 2, wherein at least a portion of the printed circuit board is located within the recess of the heat sink.

4. The printed circuit board is further coupled to the inner surface of the shaft with an electric brush, (i) The electric brush extends around at least half of the outer circumference of the heat sink, and / or, (ii) The electrosurgical tool according to claim 3, further comprising a mounting member for connecting the electric brush, the printed circuit board, and the heat sink to each other, preferably the mounting member being a band formed of a heat-shrinkable material.

5. The electric brush comprises a distal end, a proximal end, and a central part between the distal end and the proximal end, The central part has a shape corresponding to the shape of the conductive contact of the printed circuit board in the recess of the heat sink, The electrosurgical tool according to claim 4, wherein the distal end and the proximal end of the electric brush extend radially outward from the central part and directly contact the inner surface of the shaft.

6. The heat sink further comprises a biasing member in a recess extending around at least a portion of its outer circumference, The biasing member is located between the heat sink and the printed circuit board. The electrosurgical tool according to claim 2, wherein the biasing member brings the printed circuit board into contact with the inner surface of the shaft.

7. The electrosurgical tool according to any one of claims 1 to 6, wherein the printed circuit board is a flexible printed circuit board.

8. The electrosurgical tool according to any one of claims 1 to 6, further comprising a stopper assembly configured to limit the rotational movement range between the shaft and the handle to a predetermined rotational movement range.

9. The stopper assembly, A shaft stopper fixedly coupled to the proximal part of the shaft, (i) a rotating nut that is rotatably coupled to the shaft stopper, (ii) fixed to the handle in the rotational direction, and (iii) movable in the axial direction relative to the handle The electrosurgical tool according to claim 8, comprising:

10. The rotating nut is provided with a plurality of protrusions, The handle comprises a plurality of longitudinal slots, each configured to receive one of the projections of the rotating nut, The engagement between the plurality of protrusions and the plurality of longitudinal slots prevents the rotation of the rotating nut relative to the handle, while allowing axial movement of the rotating nut relative to the handle. Preferably, the electrosurgical tool according to claim 9, wherein each projection has a dovetail joint shape and each longitudinal slot has a dovetail joint shape.

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