Electrosurgical devices having adjustable lengths, methods of operating electrosurgical devices, and methods of manufacturing electrosurgical devices

Abstract

An exemplary electrosurgical device includes a handle having a proximal end and a distal end. The handle defines an internal cavity. The electrosurgical device also includes a shaft extending from the distal end of the handle. At least a portion of the shaft is within the internal cavity of the handle, and the shaft is telescopically movable relative to the handle. The electrosurgical device also includes an electrosurgical electrode extending from the distal end of the shaft and a linear actuator within the internal cavity of the handle. The linear actuator is operable to axially move the shaft relative to the handle.

Description

[Technical Field]

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority to U.S. Provisional Patent Application No. 63 / 513,005, filed July 11, 2023, and U.S. Provisional Patent Application No. 63 / 428,299, filed November 28, 2022, the contents of which are incorporated herein by reference in their entireties.

[0002] The present disclosure relates generally to electrosurgical devices, and more particularly to an electrosurgical device having a handle and an electrosurgical electrode extending from a shaft movable relative to the handle. [Background technology]

[0003] Electrosurgery involves the application of radio frequency (RF) current (also referred to as electrical energy) to biological tissue to cut, coagulate, or modify the tissue during an electrosurgical procedure. Specifically, an electrosurgical generator generates and supplies electrical current to an active electrode, which applies the current (and therefore power) to the tissue. The current flows through the tissue and returns to the generator via a return electrode (also referred to as a "dispersive electrode"). As the current flows through the tissue, the tissue impedance converts a portion of the current into thermal energy (e.g., via the principles of resistive heating), thereby increasing the temperature of the tissue and inducing tissue modification (e.g., cutting, coagulating, ablating, and / or sealing the tissue).

[0004] The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims. However, the illustrative embodiments, as well as the preferred mode of use, further objects, and description thereof, will best be understood by reference to the following detailed description of illustrative embodiments of the present disclosure when read in conjunction with the accompanying drawings. [Brief explanation of the drawings]

[0005] [Figure 1] 1 shows a schematic block diagram of an electrosurgical device according to an example. [Figure 2] 2A illustrates a first operating state of the example embodiment of the electrosurgical device shown in FIG. 1, and FIG. 2B illustrates a second operating state of the example embodiment of the electrosurgical device shown in FIG. [Figure 3] 1 illustrates a linear actuator, shaft, and sensor assembly of an electrosurgical device, according to one example. [Figure 4] FIG. 4A shows a cross-sectional view of an electrosurgical device according to an example, and FIG. 4B shows a cross-sectional view of an electrosurgical device according to an example. [Figure 5] 1 shows a flowchart of a method of operation, according to an example. [Figure 6] 6 illustrates a flowchart of a method of operation that can be used in conjunction with at least the method illustrated in FIG. 5, according to one example. [Figure 7] 7 illustrates a flowchart of a method of operation that can be used in conjunction with at least the method illustrated in FIG. 6, according to one example. [Figure 8] 6 illustrates a flowchart of a method of operation that can be used in conjunction with at least the method illustrated in FIG. 5, according to one example. [Figure 9] 10 illustrates a flowchart of a method of operation that can be used in conjunction with at least the method illustrated in FIG. 8, according to one example. [Figure 10] 6 illustrates a flowchart of a method of operation that can be used in conjunction with at least the method illustrated in FIG. 5, according to one example. [Figure 11] 6 illustrates a flowchart of a method of operation that can be used in conjunction with at least the method illustrated in FIG. 5, according to one example. [Figure 12] 12 illustrates a flowchart of a method of operation that can be used in conjunction with at least the method illustrated in FIG. 11, according to an example. [Figure 13] 6 illustrates a flowchart of a method of operation that can be used in conjunction with at least the method illustrated in FIG. 5, according to one example. [Figure 14] 6 illustrates a flowchart of a method of operation that can be used in conjunction with at least the method illustrated in FIG. 5, according to one example. [Figure 15]15 illustrates a flowchart of a method of operation that can be used in conjunction with at least the method illustrated in FIG. 14, according to an example. [Figure 16] 1 shows a flowchart of a manufacturing method, according to an example. [Figure 17] 1 shows a block diagram of an electrosurgical system, according to one example. [Figure 18A] 17 shows a perspective view of the electrosurgical device 1701 of FIG. 17, according to one example. [Figure 18B] 18 illustrates a partial cross-sectional view of the electrosurgical device of FIG. 17, according to an example. [Figure 19] 10 shows a flowchart of a method of operation according to another example. [Figure 20] 1 shows a flowchart of a manufacturing method according to another example. DETAILED DESCRIPTION OF THE INVENTION

[0006] The disclosed examples will now be described in more detail below with reference to the accompanying drawings, in which some, but not all, of the disclosed examples are shown. Indeed, several different examples may be described, and should not be construed as being limited to the examples set forth herein. Rather, these examples are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.

[0007] The terms "approximately" or "substantially" with reference to a quantity or measurement described herein mean that the characteristic, parameter, or value referred to need not be exactly achieved, but rather that deviations or variations, including, for example, tolerances, measurement errors, limitations in measurement precision, and other factors known to those skilled in the art, may occur to an extent that does not preclude the effect that the characteristic is intended to produce.

[0008] Some electrosurgical devices include a handle and an electrosurgical electrode attached to a shaft that can be extended and retracted relative to the handle. The electrode's position can be adjusted relative to the handle to assist the operator in applying current to tissue at different locations and / or depths on the patient. In some existing electrosurgical devices, adjustment typically requires the operator to stop the surgical procedure, loosen a locking nut, manually adjust the electrode position with both hands, and retighten the locking nut before performing further surgical procedures, which can be inefficient and cumbersome.

[0009] The present disclosure provides an electrosurgical device that can address one or more of the challenges of such electrosurgical devices. In an example, the electrosurgical device includes a handle having a proximal end and a distal end. The handle defines an internal cavity. The electrosurgical device also includes a shaft extending from the distal end of the handle. At least a portion of the shaft is within the internal cavity of the handle, and the shaft is telescopically movable relative to the handle. The electrosurgical device also includes an electrosurgical electrode extending from the distal end of the shaft and a linear actuator within the internal cavity of the handle. The linear actuator is operable to axially move the shaft relative to the handle. In this configuration, the linear actuator can provide automatic extension and retraction of the shaft, which can help improve operational efficiency and / or ease of use for electrosurgical devices that require manual extension and retraction of the shaft relative to the handle, as described above.

[0010] In some examples, an operator can use a linear actuator to extend or retract the electrosurgical electrode, then activate it. All of this is done while grasping the handle with one hand, without removing that hand from the handle. This makes device operation more efficient and frees the other hand to perform other surgical tasks. One-handed operation can allow the operator to control irrigation or secondary devices with their non-dominant hand, an activity that might otherwise be performed by a second person, such as a scrub tech or nurse. The increased efficiency of the device can free the second person to perform other tasks or attend to another procedure. This can help reduce the total labor time and costs required per procedure.

[0011] In some examples, the electrosurgical device can be configured to detect when the electrosurgical electrode or shaft has collided with tissue or other obstructions and disable shaft movement accordingly, which can improve safe operation of the electrosurgical device at or near a surgical site.

[0012] Figure 1 is a schematic block diagram of an electrosurgical system 100, according to one example. As shown in Figure 1, electrosurgical system 100 includes an electrosurgical generator 110 and an electrosurgical device 112. Generally, electrosurgical generator 110 is capable of generating electrosurgical energy suitable for performing electrosurgery on a patient. For example, electrosurgical generator 110 can include a power converter circuit 114 that can convert grid power into electrosurgical energy, such as, for example, radio frequency (RF) output power. By way of example, power converter circuit 114 can include one or more electrical components (e.g., one or more transformers) that can control the voltage, current, and / or frequency of the electrosurgical energy.

[0013] In an example, electrosurgical generator 110 may include a user interface 116 that may receive one or more inputs from a user and / or provide one or more outputs to a user. By way of example, 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.

[0014] In one example, user interface 116 can be operable to select an operating mode from among a plurality of operating modes for electrosurgical generator 110. By way of example, the operating modes can include a cutting mode, a coagulation mode, an ablation mode, and / or a sealing mode. Combinations of these waveforms can also be formed to create mixed modes. In one embodiment, an operating mode can correspond to a respective waveform for the electrosurgical energy. Thus, in this embodiment, 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 user interface 116.

[0015] Electrosurgical generator 110 may also include one or more generator sensors 118 capable of sensing one or more conditions related to the electrosurgical energy and / or the target tissue. By way of example, 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 examples, electrosurgical generator 110 may additionally or alternatively generate an amount (e.g., power) of electrosurgical energy and / or electrosurgical energy having a waveform selected from among a plurality of waveforms based on one or more parameters related to the conditions sensed by generator sensors 118.

[0016] In one example, the electrosurgical energy can have a frequency greater than about 100 kilohertz (kHz) to reduce (or avoid) stimulating muscles and / or nerves near the target tissue. In another example, the electrosurgical energy can have a frequency of about 300 kHz to about 500 kHz.

[0017] 1 , electrosurgical generator 110 also includes a connector 120 that can facilitate coupling of electrosurgical generator 110 to electrosurgical device 112. For example, electrosurgical device 112 can include a power cord 122 having a plug that can be coupled to a socket of connector 120 of electrosurgical generator 110. In this configuration, electrosurgical generator 110 can supply electrosurgical energy to electrosurgical device 112 via the coupling between connector 120 of electrosurgical generator 110 and power cord 122 of electrosurgical device 112.

[0018] Electrosurgical generator 110 may further include a controller 141 that can control the operation of electrosurgical generator 110. In examples, controller 141 may be implemented using hardware, software, and / or firmware. For example, controller 141 may include one or more processors and a non-transitory computer-readable medium (e.g., volatile and / or non-volatile memory) that stores machine instructions or other executable instructions. The instructions, when executed by the one or more processors, cause electrosurgical generator 110 to perform the various operations described herein. To this end, controller 141 may also receive data and store this data in memory. As shown in FIG. 1 , controller 141 may be communicatively coupled to power converter circuit 114, user interface 116, generator sensor 118, and / or connector 120.

[0019] 1 , electrosurgical device 112 can include a housing 123 having a proximal end and a distal end, and an electrosurgical electrode 128 extending from the distal end of housing 123. Housing 123 can be an elongated structure within which and / or on which components of electrosurgical device 112 can be disposed. In some examples, housing 123 can be a one-piece monolithic structure. In other examples, housing 123 can include multiple structures coupled together.

[0020] In FIG. 1 , housing 123 includes a handle 124 defining an internal cavity 145 and a shaft 126 extending distally from the distal end of handle 124. Generally, handle 124 can be configured to facilitate a user grasping and manipulating electrosurgical device 112 while performing electrosurgery. For example, handle 124 can have a shape and / or size that can facilitate a user performing electrosurgery by manipulating electrosurgical device 112 using one hand. In one embodiment, handle 124 can have a shape and / or size that can facilitate a user holding electrosurgical device 112 in a manner similar to gripping a writing instrument (e.g., electrosurgical device 112 can be an electrosurgical pencil). In another embodiment, handle 124 can have a shape and / or size that can facilitate a user holding electrosurgical device 112 in a pistol grip (e.g., handle 124 and shaft 126 can have longitudinal axes that are transverse to one another).

[0021] Additionally, for example, handle 124 and / or shaft 126 may be constructed from one or more materials (e.g., plastic materials) that are electrical insulators, which may facilitate insulating the user from the electrosurgical energy flowing through electrosurgical device 112 while performing electrosurgery.

[0022] In examples, shaft 126 is movable relative to handle 124. For example, shaft 126 can be telescopically movable relative to handle 124. In such examples, at least a portion of shaft 126 resides within an internal cavity 145 of handle 124, and shaft 126 can extend distally and retract proximally relative to handle 124 (e.g., movable along the longitudinal axis of electrosurgical device 112). As described in further detail below, electrosurgical device 112 includes one or more features that provide for automatic extension and / or retraction of shaft 126 relative to handle 124 in response to user input; these features can help improve operational efficiency and / or ease of use over electrosurgical devices that require manual extension and retraction of shaft 126 relative to handle 124.

[0023] In some examples, electrosurgical electrode 128 can be coupled to shaft 126, such that electrosurgical electrode 128 can move axially with shaft 126 along the longitudinal axis relative to handle 124. This can provide for adjustment of the length of electrosurgical device 112, thereby facilitating the performance of electrosurgery at multiple different depths within tissue (e.g., due to different patient anatomical shapes and / or sizes) and / or at multiple different angles. In other examples, electrosurgical electrode 128 can be fixedly coupled to handle 124 such that shaft 126 is axially movable relative to both electrosurgical electrode 128 and handle 124. This can provide for adjustment of the amount of electrosurgical electrode 128 exposed at the distal end of shaft 126.

[0024] In some embodiments, electrosurgical electrode 128 may additionally be rotatable about an axis of rotation parallel to the longitudinal axis of electrosurgical device 112. In some examples, electrosurgical electrode 128 may be rotatable relative to handle 124 and shaft 126. In other examples, electrosurgical electrode 128 may be rotationally fixed relative to shaft 126 such that shaft 126 and electrosurgical electrode 128 are both rotatable relative to handle 124. Rotating electrosurgical electrode 128 relative to handle 124 may facilitate adjusting the angle of electrosurgical electrode 128 relative to one or more user input devices 130 of electrosurgical device 112. In this configuration, a user may comfortably grip handle 124 in a position that allows the user's fingers to comfortably operate user input device 130, while electrosurgical electrode 128 is set to a selected one of a plurality of rotational positions relative to handle 124 based, for example, on the location, size, and / or shape of the surgical site at which the user is operating.

[0025] In one embodiment, electrosurgical electrode 128 can be rotatable greater than 360 degrees relative to handle 124. This can improve ease of use by allowing the operator to freely rotate electrosurgical electrode 128 without restriction. However, in other implementations, electrosurgical electrode 128 can be rotatable less than 360 degrees (e.g., 180 degrees, 270 degrees, or 360 degrees). This can still allow the operator to achieve a desired rotational configuration, but with the possibility that the operator can rotate in a first direction, reach a stop that limits further rotation, and then rotate back in a second direction to achieve the desired rotational configuration.

[0026] While it can be beneficial to provide for rotation of electrosurgical electrode 128 relative to handle 124 and / or shaft 126, electrosurgical electrode 128 may, in some embodiments, be rotationally fixed relative to handle 124 and shaft 126. For example, this can help to simplify and reduce the cost of manufacturing, e.g., by simplifying electrical connections (e.g., by eliminating slip ring electrical contacts and / or sliding electrical contacts) that would otherwise need to account for movement of shaft 126 and handle 124 relative to one another.

[0027] 1, electrosurgical device 112 can include one or more user input devices 130 operable to control the operation of electrosurgical device 112 and / or electrosurgical generator 110. In FIG. 1, user input devices 130 of electrosurgical device 112 include at least one shaft user input device 133 and at least one electrode user input device 135. As described further below, shaft user input device 133 is operable to move shaft 126 relative to handle 124.

[0028] Electrode user input device 135 can be operable to select between operating modes of electrosurgical device 112 and / or electrosurgical generator 110. In one embodiment, electrode user input device 135 can be configured to select between a cutting mode of operation and a coagulation mode of operation. In response to actuation of electrode user input device 135 of electrosurgical device 112, electrosurgical device 112 can (i) receive electrosurgical energy having a power level and / or waveform corresponding to the operating mode selected via user input device 130, and (ii) supply electrosurgical energy to electrosurgical electrode 128.

[0029] 1 , electrosurgical device 112 includes multiple electrical components that facilitate supplying electrosurgical energy that electrosurgical device 112 receives from electrosurgical generator 110 to electrosurgical electrode 128. For example, electrosurgical device 112 may include at least one electrical component selected from a group of electrical components including a printed circuit board 132 (e.g., a flexible printed circuit board) and / or one or more housing conductors 134 that can provide a circuit for conducting electrosurgical energy from power cord 122 to electrosurgical electrode 128. One or more of these electrical components may be positioned within an internal cavity 145 defined by handle 124 and / or within an internal bore defined by shaft 126.

[0030] In examples, printed circuit board 132 can be implemented using hardware, software, and / or firmware. For example, printed circuit board 132 can include one or more processors and a non-transitory computer-readable medium (e.g., volatile and / or non-volatile memory) that stores machine instructions or other executable instructions. The instructions, when executed by the one or more processors, cause electrosurgical device 112 to perform the various operations described herein. To this end, printed circuit board 132 can also receive data and store this data in memory.

[0031] In an example, electrode user input device 135 may include one or more buttons on the outer surface of handle 124. Each button on electrode user input device 135 may be operable to activate a respective one of a plurality of switches 136 on printed circuit board 132. Generally, switches 136 and / or printed circuit board 132 are operable to control the supply of electrosurgical energy from electrosurgical generator 110 to electrosurgical electrode 128. For example, in one embodiment, when each button is actuated (e.g., pressed), the respective switch 136 associated with the button is actuated, causing printed circuit board 132 to send a signal to electrosurgical generator 110, causing electrosurgical generator 110 to responsively supply electrosurgical energy having a power level and / or waveform corresponding to the operating mode associated with the button. In another implementation, actuation of a button, thereby actuating a respective switch 136 associated with the button, closes switch 136 and completes a circuit to electrosurgical generator 110, causing electrosurgical generator 110 to responsively supply electrosurgical energy having a power level and / or waveform corresponding to the operating mode associated with that button. In some instances of this embodiment, printed circuit board 132 may be omitted.

[0032] In any exemplary implementation, the electrosurgical energy provided by electrosurgical generator 110 can be supplied (i) from power cord 122, printed circuit board 132, and / or switch 136, and (ii) to electrosurgical electrode 128 by housing conductors 134. Thus, as shown in FIG. 1 , printed circuit board 132 can be coupled to power cord 122, printed circuit board 132 can be coupled to housing conductors 134, and housing conductors 134 can be coupled to electrosurgical electrode 128. In this configuration, housing conductors 134 can conduct electrosurgical energy to electrosurgical electrode 128. In some examples, switch 136 can be coupled to printed circuit board 132.

[0033] Generally, housing conductors 134 may each include one or more conductive elements that provide a conductive bus for supplying electrosurgical energy to electrosurgical electrode 128. In some examples, the electrical components of electrosurgical device 112 may be electrically coupled to one another in a manner suitable for supplying electrosurgical energy from power cord 122 to electrosurgical electrode 128 (i) while shaft 126 and / or electrosurgical electrode 128 move telescopically relative to handle 124, and / or (ii) while electrosurgical electrode 128 rotates relative to handle 124.

[0034] 1 , user input device 130 may, in another example, be separate from electrosurgical device 112. For example, user input device 130 may additionally or alternatively include one or more foot pedals operable to control the operation of electrosurgical device 112 as described above. The foot pedals may be communicatively coupled to electrosurgical generator 110 to provide a signal responsive to actuation of the foot pedal.

[0035] 1 , in some embodiments, electrosurgical device 112 can additionally include one or more light sources 138 configured to emit light. In some examples that include light source 138, user input device 130 can cause light source 138 to generate light that can be emitted by electrosurgical device 112 to illuminate an area of ​​interest (e.g., target tissue at a surgical site). In some embodiments, light source 138 can be located at the distal end of housing 123 and / or the distal end of shaft 126 to provide light directly in a distal direction to illuminate the surgical distal end of electrosurgical electrode 128.

[0036] 1 , light source 138 may be optically coupled to optical structure 140, which is configured to receive light emitted by light source 138 and transmit the light distally toward the surgical site to illuminate the surgical site while performing electrosurgery using electrosurgical electrode 128. Configuring light source 138 to directly illuminate the surgical field can help reduce the cost of manufacturing, for example, while transmitting light using optical structure 140 can help improve the quality of light transmitted from electrosurgical device 112 (e.g., by providing light with improved uniformity and / or reduced heat generation).

[0037] By way of example, in embodiments including an optical structure 140, the optical structure 140 can include at least one optical structure selected from the group consisting of an optical lens, a non-fiber optic light guide, and an optical fiber. When the optical structure 140 includes an optical lens (e.g., a parabolic lens, an aspheric lens, and / or a Fresnel lens), the optical structure 140 can help direct the light emitted by the light source 138 in a distal direction, thereby improving the quality of the light illuminating the surgical site. The optical structure 140 can additionally or alternatively include a non-fiber optic light guide and / or an optical fiber to transmit light over a relatively large distance in the shaft 126. For example, the light guide can transmit light in a distal direction via total internal reflection. In such embodiments, the light guide can include cladding and / or voids on the outer surface of the light guide to help promote total internal reflection. In some embodiments, the non-fiber optic light guide can be formed as a single monolithic structure.

[0038] In some examples, optical structure 140 may additionally or alternatively include other light-shaping optical elements, such as, for example, multiple facets, one or more prisms, and / or one or more optical gratings. While optical structure 140 may help improve the quality of light directed toward the surgical site, in other examples, electrosurgical device 112 may omit optical structure 140 and instead emit light directly from light source 138 onto the surgical field without transmitting light through optical structure 140.

[0039] 1 , light source 138 can be coupled to shaft 126. As such, light source 138 can also move telescopically with shaft 126 relative to handle 124. However, in other examples, light source 138 can be in an interior cavity 145 of handle 124 and / or coupled to an exterior surface of handle 124. By way of example, light source 138 can include one or more light emitting diodes (LEDs), organic light emitting diodes (OLEDs), optical fibers, non-fiber optic waveguides, and / or lenses. Additionally, for example, light source 138 can include an LED printed circuit board having one or more light sources (e.g., LEDs).

[0040] Optical structure 140 may be at the distal end of shaft 126. In some examples, optical structure 140 may circumferentially surround electrosurgical electrode 128 to emit light distally around all sides of electrosurgical electrode 128. This may help to reduce shadows and provide greater uniformity of illumination at all rotational alignments of shaft 126 relative to housing 123 and / or electrosurgical device 112 relative to the target tissue. However, in other examples, optical structure 140 may extend partially, but not entirely, around electrosurgical electrode 128.

[0041] In embodiments including a light source 138, the user input device 130, the printed circuit board 132, the switch 136, and / or the housing conductors 134 may additionally provide power to the light source 138 from a direct current (DC) power source 142. In one example, the DC power source 142 may include a battery disposed in the handle 124, the plug of the power cord 122, and / or a battery receptacle located along the power cord 122 between the handle 124 and the plug. Although the electrosurgical device 112 includes the DC power source 142 in FIG. 1 , in other examples, the DC power source 142 may be separate and distinct from the electrosurgical device 112. For example, in another example, the electrosurgical generator 110 may include the DC power source 142.

[0042] Additionally, in embodiments that include a light source 138, the user input device 130 can be operable to cause the light source 138 to emit light. In one example, the user input device 130 can include a button that independently controls the light source 138, separate from the electrode user input device 135 that controls the electrosurgical mode of operation of the electrosurgical device 112. In another example, the user input device 130 and the printed circuit board 132 can be configured such that operation of the electrode user input device 135 that controls the electrosurgical mode of operation simultaneously controls operation of the light source 138 (e.g., the light source 138 can be automatically activated to emit light when the button is operated to apply electrosurgical energy to the electrosurgical electrode 128).

[0043] 1 , in response to manipulation of user input device 130 to activate light source 138, DC power source 142 can supply power (e.g., a DC voltage) to light source 138 via printed circuit board 132 and / or housing conductors 134. In this embodiment, one or more of the conductive elements of housing conductors 134 can be configured to supply power from DC power source 142 to light source 138 and / or return power from light source 138 to DC power source 142. Thus, housing conductors 134 can additionally or alternatively help provide electrical communication between DC power source 142 and light source 138 as shaft 126 and light source 138 move telescopically relative to handle 124.

[0044] In the example described above, the user input device 130 on the handle 124 may be manipulated to control the operation of the light source 138, however, the light source 138 may additionally or alternatively be operated by one or more user input devices on the electrosurgical generator 110 (e.g., via the user interface 116) and / or on a plug in the power cord 122.

[0045] In some examples, the electrosurgical device 112 may additionally or alternatively include features for evacuating surgical smoke from the target tissue to a location outside the surgical site. Surgical smoke is a by-product of various surgical procedures. For example, during a surgical procedure, surgical smoke may be generated as a by-product of an electrosurgical unit (ESU), laser, electrocautery device, ultrasonic device, and / or other powered surgical instruments (e.g., bone saws and / or drills). In some examples, surgical smoke may contain toxic gases and / or biological products resulting from tissue destruction. In addition, surgical smoke may contain an unpleasant odor. For these and other reasons, many guidelines indicate that surgical personnel's exposure to surgical smoke should be reduced or minimized.

[0046] To reduce (or minimize) exposure to surgical smoke, a smoke evacuation system can be used during a surgical procedure. Generally, a smoke evacuation system can include a suction pump 144 capable of generating sufficient suction and / or vacuum pressure to draw the surgical smoke away from the surgical site. In some embodiments, the smoke evacuation system can be coupled to an exhaust system (e.g., an in-wall exhaust system) that exhausts the surgical smoke from the operating room. In other embodiments, the smoke evacuation system can filter the air containing the surgical smoke and return the air to the operating room. In examples, the suction pump 144 and the electrosurgical generator 110 can be provided as separate devices or integrated into a single device (e.g., within a common housing).

[0047] 1, shaft 126 may include a smoke evacuation channel 146 within an interior cavity of shaft 126. Smoke evacuation channel 146 may also include one or more smoke inlets at one or more locations around electrosurgical electrode 128. In some examples, smoke evacuation channel 146 may include multiple smoke inlets on multiple sides of electrosurgical electrode 128 and / or one or more smoke inlets extending around at least a portion of the circumference of electrosurgical electrode 128. In this configuration, the smoke inlets of smoke evacuation channel 146 may serve to receive surgical smoke into smoke evacuation channel 146 at multiple rotational orientations of electrosurgical electrode 128 relative to handle 124 and / or electrosurgical device 112 relative to target tissue.

[0048] In one example, the smoke evacuation channel 146 of the shaft 126 defines a first portion of the smoke flow path, and the interior cavity 145 of the handle 124 defines a second portion of the smoke flow path. In this configuration, surgical smoke can be received from the surgical site into the smoke evacuation channel 146 of the shaft 126 and can flow along the smoke evacuation channel 146 proximally to the interior cavity 145 of the handle 124. In the interior cavity 145 of the handle 124, the smoke can further flow to a smoke conduit 150 coupled to the proximal end of the handle 124 and configured to convey the smoke from the handle 124 to the suction pump 144.

[0049] As described above, electrosurgical electrode 128 can apply electrosurgical energy to target tissue to perform electrosurgical actions (e.g., cutting, coagulating, ablating, and / or sealing the target tissue). In an example, electrosurgical electrode 128 can include an electrosurgical substrate formed from an electrically conductive material. By way of example, the electrically conductive material can be stainless steel.

[0050] The electrosurgical substrate can extend axially from the proximal end of electrosurgical electrode 128 to the distal end of electrosurgical electrode 128. The proximal end of electrosurgical electrode 128 can receive electrosurgical energy from electrosurgical device 112 (e.g., via housing conductors 134 as described above), and the distal working portion of electrosurgical electrode 128 can apply the electrosurgical energy to target tissue. In one embodiment, the electrosurgical substrate can include a shank portion that extends from the proximal end of electrosurgical electrode 128 to the distal working portion of electrosurgical electrode 128. The distal working portion can be configured to use the electrosurgical energy for at least one of cutting or coagulating tissue in monopolar electrosurgery.

[0051] In some examples, the distal working portion can define an electrosurgical blade. For example, the electrosurgical blade can include (i) a first transverse surface, (ii) a second transverse surface opposite the first transverse surface, (iii) a first major surface on a first side of the electrosurgical blade extending between the first and second transverse surfaces, and (iv) a second major surface on a second side of the electrosurgical blade extending between the first and second transverse surfaces. The first and second transverse surfaces have relatively small surface areas compared to the surface areas of the first and second major surfaces, such that the thickness of the electrosurgical blade (e.g., the dimension between the first and second major surfaces) is relatively small compared to the length (e.g., the dimension extending between the proximal and distal ends of the electrosurgical electrode 128) and width (e.g., the dimension between the first and second transverse surfaces).

[0052] In some examples, the distal working portion of electrosurgical electrode 128 can also include an outer layer of material covering at least a portion (or all) of the electrosurgical substrate. For example, the outer layer of material can be formed from at least one material selected from the group consisting of polymeric materials, fluorocarbon materials (e.g., polytetrafluoroethylene (PTFE)), silicone, enamel, ceramic materials, and inorganic lubricating materials (e.g., titanium nitride, zirconium nitride, titanium aluminum nitride, and nitrone). The outer layer of material can, for example, inhibit eschar buildup and / or help focus electrosurgical energy on one or more portions of electrosurgical electrode 128.

[0053] In some examples, the distal working portion of the electrosurgical electrode 128 may additionally include an intermediate layer between the electrosurgical substrate and the outer layer. The intermediate layer may be configured to provide thermal conductivity that helps mitigate heating of the outer layer that leads to destruction of the outer layer. The intermediate layer may also be configured to maintain the electrical conductivity of the electrosurgical substrate so that the intermediate layer does not reduce the transmission of electrosurgical energy from the electrosurgical substrate to the target tissue.

[0054] The intermediate layer can be an anisotropic thermally conductive material in which the in-plane (e.g., parallel to the electrode surface) thermal conductivity significantly exceeds the out-of-plane (e.g., perpendicular to the electrode surface) thermal conductivity. The anisotropic thermally conductive material has a coefficient of thermal expansion that matches (or is about 10% higher or about 10% lower than) the electrosurgical substrate and outer layer. By way of example, the intermediate layer can comprise at least one material selected from the group consisting of pyrolytic graphite / carbon, graphene, and molybdenum disulfide.

[0055] As explained above, electrosurgical device 112 includes one or more features that provide for automatic extension and / or retraction of shaft 126 relative to handle 124. As shown in FIG. 1 , electrosurgical device 112 includes a linear actuator 152 within the interior cavity 145 of handle 124. Linear actuator 152 is operable to move shaft 126 axially (e.g., proximally and distally along the longitudinal axis of shaft 126) relative to handle 124.

[0056] In one example, linear actuator 152 can be an electromechanical actuator capable of converting electrical energy into linear displacement of shaft 126 relative to handle 124. For example, in the example shown in FIG. 1 , linear actuator 152 can include a motor 154 configured to convert electrical current into axial movement of shaft 126. Motor 154 can be electrically coupled (e.g., via printed circuit board 132) to DC power source 142 and / or electrosurgical generator 110 for receiving the electrical current to move shaft 126. By way of example, motor 154 can be a rotary electric motor and / or a linear motor.

[0057] Additionally, as described above, the shaft user input device 133 is configured to control the operation of the linear actuator 152 to move the shaft 126 relative to the handle 124. By way of example, the shaft user input device 133 can include one or more devices selected from the group consisting of one or more buttons, one or more rocker switches, one or more sliders, one or more dials, one or more knobs, and one or more touchpads. In one embodiment, the at least one electrode user input device 135 and the shaft user input device 133 can be operated sequentially while grasping the handle 124 with one hand, without removing the other hand from the handle 124 (e.g., the electrode user input device 135 and the shaft user input device 133 can be positioned adjacent to each other and separated by a distance within the range of motion of one finger while firmly gripping the handle 124 with the other finger). This can help to further improve operational efficiency and ease of use.

[0058] In some examples, the shaft user input device 133 is operable between a first state, a second state, and a third state. When the shaft user input device 133 is in the first state, the linear actuator 152 maintains the position of the shaft 126 relative to the handle 124. When the shaft user input device 133 is in the second state, the linear actuator 152 moves the shaft 126 distally relative to the handle 124. When the shaft user input device 133 is in the third state, the linear actuator 152 moves the shaft 126 proximally relative to the handle 124. Additionally, in one embodiment, the shaft user input device 133 can be biased toward the first state. This can help automatically stop movement of the shaft 126 in response to a user deactivating the shaft user input device 133 and hold the shaft 126 in a selected position relative to the handle 124.

[0059] In some examples, electrosurgical device 112 can be configured to (i) allow linear actuator 152 to move shaft 126 relative to handle 124 only when electrosurgical energy is not being supplied to electrosurgical electrode 128, and (ii) supply electrosurgical energy to electrosurgical electrode 128 only while shaft 126 remains axially fixed relative to handle 124 (e.g., while shaft 126 is not moving relative to handle 124). This can improve safe operation by preventing unintentional movement of shaft 126 while performing electrosurgery and / or preventing unintentional supply of electrosurgical energy while adjusting the position of shaft 126 (and, in some examples, electrosurgical electrode 128) relative to handle 124.

[0060] In one embodiment, printed circuit board 132 can be communicatively coupled to at least one electrode user input device 135 and a shaft user input device 133, and printed circuit board 132 is configured to prevent the supply of electrosurgical energy to electrosurgical electrode 128 while shaft user input device 133 is operated to move shaft 126. Also, in this embodiment, printed circuit board 132 is configured to prevent linear actuator 152 from moving shaft 126 relative to handle 124 while at least one electrode user input device 135 is operated to supply electrosurgical energy to electrosurgical electrode 128.

[0061] 1 , in some examples, electrosurgical device 112 may further include a sensor 156 configured to sense a parameter and generate a signal indicative of the position of shaft 126 relative to handle 124 based on the parameter sensed by sensor 156. Printed circuit board 132 may be communicatively coupled to sensor 156 and configured to (i) receive the signal from sensor 156, (ii) make a determination that a fault condition has occurred based on the signal, and (iii) cease operation of linear actuator 152 in response to determining that the fault condition has occurred. For example, exemplary fault conditions may include one or more conditions selected from the group consisting of: (i) a collision between shaft 126 and / or electrosurgical electrode 128 and an external object, and (ii) a jam that inhibits or prevents movement of shaft 126 relative to handle 124 (e.g., shaft 126 does not move relative to handle 124 despite current being supplied to linear actuator 152).

[0062] In another example, sensor 156 and printed circuit board 132 can be configured to stop linear actuator 152 when shaft 126 reaches a proximal end of its range of motion and / or a distal end of its range of motion relative to handle 124. For example, printed circuit board 132 can be configured to (i) receive a signal from sensor 156, (ii) determine based on the signal that shaft 126 is at the end of its range of motion (e.g., the proximal or distal end of the range of motion), and (iii) cease operation of linear actuator 152 in response to determining that shaft 126 is at the end of its range of motion. This can help reduce wear on linear actuator 152.

[0063] In another example, printed circuit board 132 can be configured to (i) store an indication of the last position of shaft 126 relative to handle 124 based on a signal received from sensor 156, and (ii) cause linear actuator 152 to move shaft 126 to the last position in response to movement of shaft 126 relative to handle 124 during an interruption of power to electrosurgical device 112. For example, shaft 126 can be manually moved relative to handle 124 while electrosurgical device 112 is unplugged from electrosurgical generator 110. In some examples, this may occur unintentionally during handling or replacement of electrosurgical electrode 128. Automatic return to the last stored position before power interruption can help improve efficiency of operation and ease of use.

[0064] By way of example, the sensor 156 may additionally or alternatively include one or more sensors selected from the group consisting of a potentiometric position sensor, an inductive position sensor, an eddy current-based position sensor, a capacitive position sensor, a magnetoresistive position sensor, a Hall effect sensor, a fiber optic position sensor, an optical position sensor, and an ultrasonic position sensor. In one example, the sensor 156 may be an anisotropic magnetoresistive (AMR) sensor. This may be advantageous at least because AMR sensors are contactless sensors, which may help to extend the service life of the sensor 156, reduce the overall power budget, and / or reduce wear on the sensor 156 (or other components that would otherwise contact the sensor 156). Also, in an example, the parameter may be the current used by the motor 154 of the linear actuator 152 to move the shaft 126.

[0065] Figures 2A-2B show cross-sectional views of electrosurgical device 112 according to an exemplary embodiment of electrosurgical device 112 shown in Figure 1. In particular, Figure 2A shows a cross-sectional view taken through the longitudinal axis while shaft user input device 133 is operated to extend shaft 126 relative to handle 124, and Figure 2B shows a cross-sectional view taken through the longitudinal axis while shaft user input device 133 is operated to retract shaft 126 relative to handle 124.

[0066] 2A-2B, handle 124 has a proximal end 224A and a distal end 224B, and handle 124 defines an internal cavity 145. Shaft 126 extends from distal end 224B of handle 124. At least a portion of shaft 126 is within internal cavity 145 of handle 124, and shaft 126 is telescopically movable relative to handle 124. For example, at least proximal end 226A of shaft 126 is within internal cavity 145. Electrosurgical electrode 128 extends from distal end 226B of shaft 126.

[0067] In this example, electrosurgical device 112 includes two electrode user input devices 235A, 235B operable to control the supply of electrosurgical energy to electrosurgical electrode 128. Electrode user input devices 235A, 235B can be configured to operate electrosurgical device 112 according to different operating modes. For example, operating electrode user input device 235A can cause electrosurgical energy to be supplied to electrosurgical electrode 128 according to a first mode (e.g., electrosurgical energy can have a first power, a first waveform, a first frequency, etc.), and operating electrode user input device 235B can cause electrosurgical energy to be supplied to electrosurgical electrode 128 according to a second mode (e.g., electrosurgical energy can have a second power, a second waveform, a second frequency, etc.). 2A-2B, electrode user input devices 235A, 235B are shown as buttons, however, electrode user input devices 235A, 235B can take different forms in other examples (e.g., electrode user input devices 235A, 235B can include one or more devices selected from the group consisting of one or more buttons, one or more rocker switches, one or more sliders, one or more dials, one or more knobs, and one or more touchpads). Additionally, although electrosurgical device 112 includes two electrode user input devices 235A, 235B in Figures 2A-2B, in other examples, electrosurgical device 112 may include one or more than two electrode user input devices 235A, 235B.

[0068] 2A-2B , the linear actuator 152 resides within the interior cavity 145 of the handle 124, and the linear actuator 152 is operable to axially move the shaft 126 relative to the handle 124. In this example, the linear actuator 152 is fixedly disposed in a proximal portion of the handle 124 such that the linear actuator 152 does not move relative to the handle 124 while the linear actuator 152 moves the shaft 126. In one embodiment, the handle 124 may include one or more ribs extending inwardly from an inner wall of the handle 124 to limit or prevent movement of the linear actuator 152 relative to the handle 124.

[0069] The shaft user input device 133 is configured to control the operation of the linear actuator 152 to move the shaft 126 relative to the handle 124. In this example, the shaft user input device 133 includes a rocker switch having a first state, a second state, and a third state as described above. However, in other examples, the shaft user input device 133 may be configured differently. In the example shown in FIGS. 2A-2B , the electrode user input devices 235A, 235B and the shaft user input device 133 are sequentially operable while holding the handle 124 with one hand, without removing the other hand from the handle 124.

[0070] Although not shown in FIGS. 2A-2B , when the shaft user input device 133 is not actuated, the shaft user input device 133 is biased to a first state, and in the first state, the linear actuator 152 maintains the position of the shaft 126 relative to the handle 124. In one example, the shaft user input device 133 may include a biasing member, such as a spring, that biases a rocker switch from the second state to the first state and from the third state to the first state. As shown in FIG. 2A , when the shaft user input device 133 is in the second state, the linear actuator 152 moves the shaft 126 distally relative to the handle 124. As shown in FIG. 2B , when the shaft user input device 133 is in the third state, the linear actuator 152 moves the shaft 126 proximally relative to the handle 124.

[0071] As explained above, in some embodiments, the electrosurgical device 112 can include a sensor 156. Figure 3 shows the assembly of the linear actuator 152, a portion of the shaft 126, and the printed circuit board 132, according to one example. As explained above, the linear actuator 152, a portion of the shaft 126, and the printed circuit board 132 can be located within the interior cavity 145 of the handle 124.

[0072] The sensor 156 can be configured to sense a parameter and generate a signal indicative of the axial position of the shaft 126 relative to the handle 124 based on the parameter sensed by the sensor 156. Additionally, in FIG. 3 , the printed circuit board 132 can be communicatively coupled to the sensor 156 and configured to receive the signal from the sensor 156. The printed circuit board 132 can be further configured to determine, based on the signal, that a fault condition has occurred (e.g., a collision has occurred and / or a jam has occurred). In response to determining that a fault condition has occurred, the printed circuit board 132 can cease operation of the linear actuator 152.

[0073] Additionally or alternatively, the printed circuit board 132 may store an indication of the final position of the shaft 126 relative to the handle 124 and cause the linear actuator 152 to move the shaft 126 to the final position in response to movement of the shaft 126 relative to the handle 124 during an interruption of power to the electrosurgical device 112.

[0074] In an example, electrosurgical device 112 receives a first input via shaft user input device 133 and, in response to receiving the first input, moves shaft 126 axially relative to handle 124 via linear actuator 152. For example, the first input is a first type of input received by a distal portion of shaft user input device 133, and linear actuator 152 moves shaft 126 in a distal direction relative to handle 124. In addition, shaft user input device 133 receives a second type of input, for example, at a proximal portion of shaft user input device 133, and linear actuator 152 moves shaft 126 in a proximal direction relative to handle 124 in response to receiving the second type of input.

[0075] In some examples, the electrode user input device 135, 235A, 235B receives a third input and the electrosurgical generator 110 provides electrical energy to the electrosurgical electrode 128 in response to receiving the third input.

[0076] Additionally or alternatively, one or more of sensor 156 and / or printed circuit board 132 may detect that shaft user input device 133 is not being operated (e.g., not receiving input) and, in response to the detection, enable electrode user input device 135 such that receipt of input at electrode user input device 135 causes electrical energy to be provided from electrosurgical generator 110 to electrosurgical electrode 128. Thus, in this example, electrosurgical electrode 128 is only enabled when it is determined that shaft user input device 133 is not being used to move shaft 126 relative to handle 124.

[0077] In some examples, one or more of sensors 156 and / or printed circuit boards 132 may detect that shaft user input device 133 is being manipulated and, in response to detecting that shaft user input device 133 is being manipulated, disable electrode user input device 135 such that receipt of an input at electrode user input device 135 prevents electrical energy from being provided from electrosurgical generator 110 to electrosurgical electrode 128. Thus, in this example, electrosurgical electrode 128 is disabled due to it being determined that shaft user input device 133 is currently being used to move shaft 126 relative to handle 124.

[0078] 4A and 4B are cross-sectional views of an electrosurgical device 412 according to another exemplary embodiment. Electrosurgical device 412 is substantially similar to or identical to electrosurgical device 112 shown and described with respect to FIGS. 1-3, except that electrosurgical device 412 shown in FIGS. 4A-4B includes a gearbox 458.

[0079] 4A-4B, gearbox 458 can be coupled to linear actuator 152 and shaft 126 (e.g., between linear actuator 152 and shaft 126). Gearbox 458 can include multiple gears that can be configured to control the speed at which shaft 126 moves relative to handle 124. For example, the gears of gearbox 458 can have a gear ratio that can receive input mechanical power from linear actuator 152 and provide output mechanical power to shaft 126. In some examples, the input mechanical power can be less than the output mechanical power. In other examples, the input mechanical power can be greater than the output mechanical power.

[0080] In some examples, the gearbox 458 may additionally or alternatively be configured to reduce backlash when the linear actuator 152 is used to move the shaft 126 .

[0081] 5 is a flowchart of a process 500 for operating an electrosurgical device. As shown in FIG. 5, at block 510, process 500 includes receiving a first input via a shaft user input device of the electrosurgical device. At block 512, process 500 includes automatically moving a shaft of the electrosurgical device axially relative to a handle of the electrosurgical device via a linear actuator of the electrosurgical device in response to receiving the first input. The electrosurgical device can include an electrosurgical electrode extending from a distal end of the shaft.

[0082] 6-15 illustrate additional aspects of process 500 according to further examples. As shown in FIG. 6, receiving a first input at block 510 can include receiving a first type of input at block 514, and automatically moving the shaft at block 512 can include moving the shaft distally relative to the handle at block 516.

[0083] As shown in FIG. 7, process 500 may also include, at block 518, receiving a second type of input via the shaft user input device, and, at block 520, automatically moving the shaft proximally relative to the handle via the linear actuator in response to receiving the second type of input.

[0084] As shown in FIG. 8 , receiving a first input at block 510 can include receiving a first type of input at block 522, and moving the shaft at block 512 can include moving the shaft in a proximal direction relative to the handle at block 524.

[0085] As shown in FIG. 9 , the process 500 may also include, at block 526, receiving a second type of input via the shaft user input device, and, at block 528, automatically moving the shaft distally relative to the handle via the linear actuator in response to receiving the second type of input.

[0086] As shown in FIG. 10 , process 500 may also include, at block 530, receiving a third input via an electrode user input device of the electrosurgical device, and, at block 532, providing electrical energy from an electrosurgical energy supply to the electrosurgical electrode in response to receiving the third input.

[0087] As shown in FIG. 11 , process 500 may also include, at block 534, detecting that the shaft user input device is not being manipulated, and, in response to the detection, at block 536, enabling the electrode user input device such that receipt of an input at the electrical user input device causes electrical energy to be provided from the electrosurgical energy supply to the electrosurgical electrode.

[0088] As shown in FIG. 12 , process 500 may also include, at block 538, detecting that the shaft user input device is being manipulated, and, at block 540, disabling the electrode user input device in response to detecting that the shaft user input device is being manipulated, such that receipt of an input at the electrode user input device does not result in electrical energy being provided from the electrosurgical energy supply to the electrosurgical electrode.

[0089] As shown in FIG. 13, the process 500 may also include, at block 542, sensing the position of the shaft relative to the handle and, at block 544, generating an output indicative of the position of the shaft relative to the handle.

[0090] As shown in FIG. 14, the process 500 may also include, at block 546, receiving a signal from a sensor indicating a fault condition, and, at block 548, ceasing operation of the linear actuator in response to receiving the signal.

[0091] As shown in FIG. 15, process 500 also includes, in block 550, storing the position of the shaft relative to the handle corresponding to when the fault condition occurred, and, in block 552, causing the linear actuator to move the shaft to that position in response to movement of the shaft relative to the handle while power to the electrosurgical device is interrupted.

[0092] FIG. 16 is a flowchart of a process 1600 for manufacturing an electrosurgical device. At block 1610, the process 1600 includes forming a handle having a proximal end and a distal end, the handle defining an internal cavity. At block 1612, the process 1600 includes coupling a shaft to the handle, the shaft extending from the distal end of the handle and at least a portion of the shaft within the internal cavity of the handle. The shaft is telescopically movable relative to the handle. At block 1614, the process 1600 includes coupling an electrosurgical electrode to the distal end of the shaft. At block 1616, the process 1600 includes disposing a linear actuator within the internal cavity of the handle. At block 1618, the process 1600 includes coupling the linear actuator to the shaft such that the linear actuator is operable to axially move the shaft relative to the handle.

[0093] 1-16 include a linear actuator that can be commanded via an electrical signal to move shaft 126 and electrosurgical electrode 128. In other exemplary embodiments, shaft 126 and electrosurgical electrode 128 can be moved manually, thereby reducing complexity and cost.

[0094] 17 is a block diagram of an electrosurgical electrode system 1700, according to one example. Electrosurgical system 1700 is similar to electrosurgical system 100, and like components are labeled with like reference numbers.

[0095] Electrosurgical system 1700 includes electrosurgical generator 110 and electrosurgical device 1701. Electrosurgical device 1701 is similar to electrosurgical device 112. However, rather than using a linear actuator 152 and motor 154 to cause linear movement (e.g., extension and retraction) of electrosurgical electrode 128, electrosurgical device 1701 includes a roller 1702 configured to interact with a shaft 1704. Roller 1702 is configured to be at least partially exposed or protrude from a housing 1706 of electrosurgical device 1701 and to allow an operator to have access to and manipulate (e.g., rotate) roller 1702.

[0096] Roller 1702 engages (directly or indirectly) shaft 1704. In particular, roller 1702 is configured to interact with shaft 1704 such that rotation of roller 1702 by an operator causes linear movement of shaft 1704 and the electrosurgical electrode 128 coupled thereto.

[0097] In one example, roller 1702 can be formed as a wheel that interacts with at least a portion of shaft 1704. In one example, the wheel can be formed as a gear (e.g., an involute gear), and shaft 1704 can have a rack with teeth formed thereon. The gear teeth of roller 1702 engage with the teeth of the rack of shaft 1704.

[0098] Thus, in this example, roller 1702 and shaft 1704 form a rack and pinion configuration, where shaft 126 acts as the rack and roller 1702 acts as the pinion. With this configuration, rotation of roller 1702 causes linear movement of shaft 1704.

[0099] In another example, roller 1702 can frictionally engage shaft 1704. In other words, roller 1702 can have a roughened surface or a surface coated with a light adhesive. Portions of shaft 1704 can have a roughened surface or a light adhesive applied thereto. In this manner, rotation of roller 1702 causes linear movement of shaft 1704.

[0100] Figure 18A shows a perspective view of electrosurgical device 1701, and Figure 18B shows a partial cross-sectional view of electrosurgical device 1701, according to one example. Figures 18A and 18B are described together.

[0101] As shown, housing 1706 has a window or opening 1800. Roller 1702 is partially disposed within interior cavity 145 of housing 1706 and protrudes outwardly through opening 1800 so as to be accessible from the exterior of housing 1706 by an operator handling electrosurgical device 1701. In the illustrative embodiment of Figures 18A-18B, roller 1702 is illustratively formed as a gear having involute gear teeth.

[0102] Similar to shaft 126, shaft 1704 is disposed within interior cavity 145 of housing 1706. Shaft 1704 has a proximal end or base 1802. Base 1802 may be generally cylindrical and may have a smooth outer surface.

[0103] The shaft 1704 also has a distal end or head 1804. The head 1804 may be generally cylindrical and may have a smooth outer surface.

[0104] The shaft 1704 further includes a rack portion 1806 interposed between the base 1802 and the head 1804. As shown, the rack portion 1806 has teeth formed thereon. In particular, in the exemplary embodiment of FIGS. 18A-18B, the teeth of the rack portion 1806 may be circumferential teeth that may extend around substantially the entire circumference of the rack portion 1806. In other words, each of the teeth of the rack portion 1806 may be formed as a disk or thread formed on the shaft 1704.

[0105] This configuration ensures that the teeth of rack portion 1806 engage with the teeth of roller 1702 regardless of the rotational position of shaft 1704. Thus, in an exemplary embodiment in which shaft 1704 is rotatable to orient electrosurgical electrode 128 as desired, rack portion 1806 maintains engagement with roller 1702, facilitating linear movement of shaft 1704 regardless of the rotational position of shaft 1704.

[0106] However, in other exemplary embodiments, the teeth of rack portion 1806 can project in only one direction rather than spanning the entire circumference of rack portion 1806. For example, if shaft 1704 is not rotatable, continuous engagement between roller 1702 and rack portion 1806 can be achieved using teeth that project only toward roller 1702 rather than in all directions. In other examples, rather than teeth, rack portion 1806 can be serrated so that interaction with rack portion 1806 causes linear movement of shaft 1704 as roller 1702 rotates.

[0107] In operation, an operator has access to roller 1702, which protrudes outwardly through opening 1800 in housing 1706. Thus, when the operator rotates roller 1702 with their fingers, roller 1702 moves shaft 1704 linearly within interior cavity 145 of housing 1706. As a result, the linear position of electrosurgical electrode 128 can be linearly adjusted by the operator as desired. With this configuration, the axis about which roller 1702 rotates is perpendicular to the longitudinal axis along which shaft 1704 and electrosurgical electrode 128 move linearly.

[0108] The description of different advantageous configurations has been presented for purposes of illustration and description and is not intended to be exhaustive or limited to the disclosed forms of the embodiments. Many modifications and variations will be apparent to those skilled in the art. Moreover, different advantageous embodiments may offer different advantages over other advantageous embodiments. The selected embodiment(s) have been chosen and described to explain the principles, practical applications of the embodiments, and to enable those skilled in the art to understand the present disclosure in terms of various embodiments, including various modifications suitable for the particular applications intended.

[0109] 19 , a flowchart of a method 1900 of operating an electrosurgical device is shown, according to one example. At block 1910, method 1900 includes providing an electrosurgical device. The electrosurgical device includes a housing having an internal cavity, the housing having an opening. The electrosurgical device also includes (i) a shaft at least partially disposed within the internal cavity of the housing, (ii) an electrosurgical electrode extending from a distal end of the shaft, and (iii) a roller partially disposed within the internal cavity of the housing and extending through the opening in the housing to be accessible outside the housing. The roller engages the shaft such that rotation of the roller causes the shaft and electrosurgical electrode to move linearly relative to the housing. At block 1912, method 1900 also includes rotating the roller relative to the housing to cause the shaft and electrosurgical electrode to move linearly relative to the housing.

[0110] Referring now to FIG. 20 , a flowchart of a method 2000 of manufacturing an electrosurgical device is shown, according to one example. At block 2010, method 2000 includes forming a housing having an internal cavity. The housing has an opening. At block 2012, method 2000 includes disposing a shaft at least partially within the internal cavity of the housing. At block 2014, method 2000 includes coupling an electrosurgical electrode to the shaft such that the electrosurgical electrode extends from a distal end of the shaft. At block 2016, method 2000 includes disposing a roller partially within the internal cavity of the housing and extending through the opening in the housing to be accessible outside the housing. The roller engages the shaft such that rotation of the roller causes the shaft and electrosurgical electrode to move linearly relative to the housing.

[0111] It is also contemplated that any optional features of the described inventive variations may be described and claimed independently or in combination with one or more of the features described herein. Similarly, reference to a singular item includes the possibility that there are plural items of the same kind. More particularly, 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. It is further noted that the claims may be drafted to exclude optional elements. Accordingly, this statement is intended to serve as a predicate for the use of exclusive terms such as "solely," "only," and the like, or the use of a "negative" limitation in connection with the recitation of claim elements. Unless otherwise defined, all technical and scientific terms used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this invention belongs. The scope of this application is not limited by this specification, but rather only by the ordinary meaning of the claim terms used.

Claims

1. 1. An electrosurgical device comprising: a handle having a proximal end and a distal end and defining an interior cavity; a shaft extending from the distal end of the handle, at least a portion of which is within the interior cavity of the handle, and which is telescopically movable relative to the handle; an electrosurgical electrode extending from the distal end of the shaft; a linear actuator disposed within the interior cavity of the handle and operable to axially move the shaft relative to the handle; An electrosurgical device comprising:

2. The electrosurgical device of claim 1 , wherein the linear actuator comprises a motor configured to convert an electrical current into axial movement of the shaft.

3. further comprising an electrode user input device and a shaft user input device; the electrode user input device is operable to control the delivery of electrosurgical energy to the electrosurgical electrode; The electrosurgical device of claim 1 , wherein the shaft user input device is configured to control operation of the linear actuator to move the shaft relative to the handle.

4. the shaft user input device is operable between a first state, a second state, and a third state; when the shaft user input device is in the first state, the linear actuator maintains the position of the shaft relative to the handle; when the shaft user input device is in the second state, the linear actuator moves the shaft distally relative to the handle; The electrosurgical device of claim 3, wherein the linear actuator moves the shaft proximally relative to the handle when the shaft user input device is in the third state.

5. The electrosurgical device according to claim 4 , wherein the shaft user input device is biased toward the first state.

6. The electrosurgical device of any one of claims 3 to 5, wherein the electrode user input device and the shaft user input device are operable sequentially while gripping the handle with one hand without removing the other hand from the handle.

7. a printed circuit board communicatively coupled to the electrode user input device and the shaft user input device; 7. The electrosurgical device of claim 3, wherein the printed circuit board is configured to block supply of electrosurgical energy to the electrosurgical electrode while the shaft user input device is manipulated to move the shaft.

8. The electrosurgical device according to claim 7, wherein the printed circuit board is configured to prevent the linear actuator from moving the shaft relative to the handle while the electrode user input device is operated to supply the electrosurgical energy to the electrosurgical electrode.

9. The electrosurgical device of any preceding claim, further comprising a sensor configured to sense a parameter and to generate a signal indicative of a position of the shaft relative to the handle based on the sensed parameter.

10. further comprising a printed circuit board communicatively coupled to the sensor; The printed circuit board is receiving the signal from the sensor; determining, based on the signal, that a fault condition has occurred; The electrosurgical device of claim 9, configured to cease operation of the linear actuator in response to determining that the fault condition has occurred.

11. The electrosurgical device of claim 10, wherein the sensor is an anisotropic magnetoresistive (AMR) sensor.

12. The electrosurgical device of claim 10, wherein the parameter is a current used by a motor of the linear actuator to move the shaft.

13. The printed circuit board is storing an indication of a final position of the shaft relative to the handle based on the signal; The electrosurgical device of any one of claims 10 to 12, configured to cause the linear actuator to move the shaft to the final position in response to movement of the shaft relative to the handle while power to the electrosurgical device is interrupted.

14. 1. A method of operating an electrosurgical device, comprising: receiving a first input via a shaft user input device of the electrosurgical device; automatically moving a shaft of the electrosurgical device axially relative to a handle of the electrosurgical device in response to receiving the first input via a linear actuator of the electrosurgical device, the electrosurgical device including an electrosurgical electrode extending from a distal end of the shaft; A method comprising:

15. 15. The method of claim 14, wherein receiving the first input comprises receiving a first type of input, and automatically moving the shaft comprises moving the shaft distally relative to the handle.

16. receiving a second type of input via the shaft user input device; automatically moving the shaft proximally relative to the handle via the linear actuator in response to receiving the second type of input; 16. The method of claim 15, further comprising:

17. 15. The method of claim 14, wherein receiving the first input comprises receiving an input of a first type, and moving the shaft comprises moving the shaft proximally relative to the handle.

18. receiving a second type of input via the shaft user input device; moving the shaft distally relative to the handle via the linear actuator in response to receiving the second type of input; 20. The method of claim 17, further comprising:

19. receiving a third input via an electrode user input device of the electrosurgical device; providing electrical energy from an electrosurgical energy supply to the electrosurgical electrode in response to receiving the third input; The method of any one of claims 14 to 18, further comprising:

20. detecting that the shaft user input device is not being operated; enabling an electrode user input device in response to said sensing such that receipt of an input at the electrode user input device causes electrical energy to be provided to the electrosurgical electrode from an electrosurgical energy supply; The method of any one of claims 14 to 19, further comprising:

21. detecting that the shaft user input device is being operated; disabling the electrode user input device in response to detecting that the shaft input device has been manipulated such that electrical energy is not provided from the electrosurgical energy supply to the electrosurgical electrode upon receipt of an input at the electrode user input device; 21. The method of claim 20, further comprising:

22. sensing a position of the shaft relative to the handle; generating an output indicative of the position of the shaft relative to the handle; The method of any one of claims 14 to 21, further comprising:

23. receiving a signal from a sensor indicative of a fault condition; responsive to receiving the signal, ceasing operation of the linear actuator; The method of any one of claims 14 to 22, further comprising:

24. storing a position of the shaft relative to the handle corresponding to when the fault condition occurred; causing the linear actuator to move the shaft to the position in response to movement of the shaft relative to the handle while power to the electrosurgical device is interrupted; 24. The method of claim 23, further comprising:

25. 1. A method of manufacturing an electrosurgical device, comprising: forming a handle having a proximal end and a distal end, the handle defining an internal cavity; coupling a shaft to the handle such that the shaft extends from the distal end of the handle and at least a portion of the shaft is within the interior cavity of the handle, the shaft being telescopically movable relative to the handle; coupling an electrosurgical electrode to the distal end of the shaft; disposing a linear actuator within the interior cavity of the handle; coupling the linear actuator to the shaft such that the linear actuator axially moves the shaft relative to the handle; A method comprising:

26. 1. An electrosurgical device comprising: a housing having an internal cavity and having an opening; a shaft disposed at least partially within the interior cavity of the housing; an electrosurgical electrode extending from the distal end of the shaft; a roller disposed partially within the interior cavity of the housing and extending through the opening in the housing so as to be accessible from the exterior of the housing, the roller engaging the shaft such that rotation of the roller causes linear movement of the shaft and the electrosurgical electrode relative to the housing; An electrosurgical device comprising:

27. The electrosurgical device according to claim 26, wherein the axis about which the roller rotates is perpendicular to the longitudinal axis about which the shaft and electrosurgical electrode move linearly.

28. 28. The electrosurgical device of claim 26 or 27, wherein the shaft includes a rack portion having teeth formed thereon, and the rollers are formed as gears with respective teeth that engage the teeth of the rack portion.

29. 29. The electrosurgical device according to claim 28, wherein the teeth on the rack portion are configured as circumferential teeth around substantially the entire circumference of the rack portion, whereby engagement between the roller and the rack portion is maintained regardless of the rotational position of the shaft.

30. The electrosurgical device of any one of claims 26 to 29, wherein the shaft has serrations that engage the rollers to promote linear movement of the shaft upon rotation of the rollers.

31. The electrosurgical device of any one of claims 26 to 30, wherein the roller is frictionally engaged with the shaft to facilitate linear movement of the shaft upon rotation of the roller.

32. 1. A method of operating an electrosurgical device, comprising: Providing an electrosurgical device, said device comprising: a housing having an internal cavity, the housing having an opening; a shaft disposed at least partially within the interior cavity of the housing; an electrosurgical electrode extending from the distal end of the shaft; a roller disposed partially within the interior cavity of the housing and extending through the opening in the housing so as to be accessible outside the housing; Equipped with providing a roller that engages the shaft such that rotation of the roller causes the shaft and the electrosurgical electrode to move linearly relative to the housing; rotating the roller relative to the housing to cause the shaft and the electrosurgical electrode to move linearly relative to the housing; A method comprising:

33. 1. A method of manufacturing an electrosurgical device, comprising: forming a housing having an internal cavity, the housing having an opening; disposing a shaft at least partially within the interior cavity of the housing; coupling an electrosurgical electrode to the shaft such that the electrosurgical electrode extends from the distal end of the shaft; providing a roller partially within the interior cavity of the housing and extending through the opening in the housing so as to be accessible outside the housing; Including, The roller engages the shaft such that the rotation of the roller causes the shaft and the electrosurgical electrode to move linearly relative to the housing.

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