Forceps Motion Transmission Assembly

Abstract

The forceps includes a frame and a motion transmission assembly for transmitting force from one or more actuators to the end effector. The motion transmission assembly may include a body having a passageway, a drive shaft extending through the passageway, and a drive link. The body and drive shaft are slidable relative to the frame, and the body is rotationally fixed to the drive shaft to transmit rotational input received from a first actuator to rotational movement of the drive shaft relative to the frame. The drive link, operably coupled to the frame and body, transmits force received from a second actuator to linear movement of the body and drive shaft relative to the frame.

Description

[Technical field]

[0001] (Priority Claim) This application claims priority to U.S. patent application Ser. No. 62 / 826,532, entitled "BLADE ASSEMBLY FOR FORCEPS," filed Mar. 29, 2019, the disclosure of which is incorporated by reference in its entirety.

[0002] This application also claims priority to U.S. patent application Ser. No. 62 / 826,522, filed Mar. 29, 2019, entitled “SLIDER ASSEMBLY FOR FORCEPS,” the disclosure of which is incorporated by reference in its entirety.

[0003] This application also claims priority to U.S. patent application Ser. No. 62 / 841,476, entitled "FORCEPS WITH CAMMING JAWS," filed May 1, 2019, the disclosure of which is incorporated by reference in its entirety.

[0004] This application also claims priority to U.S. patent application Ser. No. 62 / 994,220, entitled "FORCEPS DEVICES AND METHODS," filed March 24, 2020, the disclosure of which is incorporated by reference in its entirety.

[0005] This document relates generally, but not exclusively, to systems and methods for actuating an end effector of a medical device. In particular, the systems and methods may be used with forceps having actuable jaws and / or blades. [Background technology]

[0006] Diagnostic and therapeutic medical devices, including but not limited to forceps, are used in medical procedures such as laparoscopic and open surgery. Forceps can be used to manipulate, engage, grasp, or otherwise affect an anatomical feature, such as a blood vessel or another tissue. Such medical devices can include an end effector that is one or more of rotatable, openable, closeable, extendable, retractable, and capable of providing an input, such as electromagnetic energy or ultrasound.

[0007] For example, jaws located at the distal end of the forceps are typically actuated via elements in the forceps' handpiece to open and close the jaws to thereby engage a blood vessel or other tissue. Forceps may also include an extendable and retractable blade, such as a blade that can be extended distally between a pair of jaws.

[0008] There is a need for improved medical devices, including forceps. The aspects described herein provide various improvements over conventional forceps and other medical devices having a handpiece that includes an actuation system to control an end effector. Summary of the Invention [Means for solving the problem]

[0009] In the drawings, they are not necessarily drawn to scale, and like numbers may describe like components in different figures. Like numbers with different letter suffixes may represent different instances of like components. The drawings illustrate generally, by way of example, but not by way of limitation, various embodiments discussed in the present document. [Brief description of the drawings]

[0010] [Figure 1A] FIG. 2 illustrates a side view of the forceps showing the jaws in an open position. [Figure 1B] FIG. 1B illustrates a side view of the forceps of FIG. 1A showing the jaws in a closed position. [Diagram 2] FIG. 1B illustrates an exploded view of some components of the forceps of FIG. 1A. [Figure 3A] 1B shows a first partial cross-sectional view of a portion of the forceps of FIG. 1A. [Figure 3B] 1B shows a second partial cross-sectional view of a portion of the forceps of FIG. 1A. [Figure 3C] 1B shows an enlarged exploded view of a portion of the forceps of FIG. 1A. [Figure 3D] 3B illustrates a third partial cross-sectional view of the forceps of FIG. 3A, depicting the drive shaft motion transmission body in a rotated position. [Figure 3E] FIG. 3D illustrates a fourth partial cross-sectional view of the forceps of FIG. 3A, depicting the drive shaft motion transmission body in the rotated position of FIG. 3D. [Figure 4A] 1B shows a partial cross-sectional view of the forceps of FIG. 1A depicting the lever in a distal position (e.g., a non-actuated position). [Figure 4B] 1B illustrates a partial cross-sectional view of the forceps of FIG. 1A showing the lever moved in a proximal direction (eg, to an actuated position). [Figure 4C] 1B illustrates a partial cross-sectional view of the forceps of FIG. 1A showing the lever moved further proximally (eg, in a force-limiting, overtravel position). [Figure 5A] 1B illustrates an exploded view of a portion of the forceps of FIG. 1A including a drive shaft motion transmission assembly, which includes a drive shaft motion transmission body, a clip, a drive shaft, and a spring. [Figure 5B] FIG. 5B shows an isometric view of the drive shaft motion transmission of FIG. 5A in an assembled state. [Figure 5C] FIG. 5B shows an isometric view of the drive shaft motion transmission assembly of FIG. 5A in an assembled state (compressed, with the spring in a preloaded position). [Figure 6A] 5B shows a partial exploded view of the drive shaft motion transmission assembly of FIG. 5A, depicting the drive shaft motion transmission body assembled on the drive shaft. [Figure 6B] FIG. 5B shows an isometric view of the drive shaft motion transmission assembly of FIG. 5A in a partially assembled state, with the spring shown in cross section. [Figure 6C]5B shows an isometric view of the drive shaft motion transmission assembly of FIG. 5A with the spring shown in cross section. [Figure 7A] 1B shows an isometric view of a second example of a drive shaft motion transmission assembly that can be used with the forceps of FIG. 1A. [Figure 7B] 7B shows an exploded view of a second example of the drive shaft motion transmission assembly of FIG. 7A. [Figure 8A] 1B shows an isometric view of a third example of a drive shaft motion transmission assembly that can be used with the forceps of FIG. 1A. [Figure 8B] 8B shows an exploded view of a third example of the drive shaft motion transmission assembly of FIG. 8A. [Figure 9A] FIG. 1B shows an isometric view of a fourth example of a drive shaft motion transmission assembly that can be used with the forceps of FIG. 1A. [Figure 9B] 9B shows an exploded view of a fourth example of the drive shaft motion transmission assembly of FIG. 9A. [Figure 10A] 1B shows a side view of a portion of the forceps of FIG. 1A, with the rotational actuator represented in phantom. [Figure 10B] 10B is a cross-sectional view of the rotary actuator and outer hub shown in FIG. 10A taken along line 10B-10B', with the rotary actuator represented in solid lines. [Figure 11A] 1B shows a side view of a portion of the forceps of FIG. 1A with the outer hub represented in phantom. [Figure 11B] 11B is a cross-sectional view of the outer hub and drive body shown in FIG. 11A taken along line 11B-11B', with the outer hub represented in solid lines. [Figure 12] 13 shows a partial cross-sectional view of another example of a drive shaft motion transmission with an anchor portion including an anti-rotation key and an outer hub including a rotational keying slot. [Figure 13A] 1B illustrates a side view of a portion of the forceps of FIG. 1A with the lever in an inactivated position (eg, retracted). [Figure 13B] FIG. 1B shows a side view of the forceps portion of FIG. 1A with the lever in an actuated position. [Figure 13C]FIG. 1B illustrates a side view of the forceps portion of FIG. 1A with the lever in a force-limiting state (e.g., overtravel position). [Figure 14A] FIG. 1B shows a side view of the drive link of the forceps of FIG. 1A. [Figure 14B] FIG. 1B shows a proximal isometric view of the drive link of the forceps of FIG. 1A. [Figure 14C] FIG. 1B shows a distal isometric view of the drive link of the forceps of FIG. 1A. [Figure 15A] FIG. 1B illustrates a side view of a portion of the forceps of FIG. 1A with the first lever in an actuated position and the trigger in an unactuated position. [Figure 15B] FIG. 1B illustrates a side view of a portion of the forceps of FIG. 1A with the first lever in an actuated position and the second actuator in a non-actuated position. [Figure 16A] 16A shows a cross-sectional view of a portion of the forceps of FIG. 1A taken along line 16A-16A' of FIG. 15A, with the trigger in the unactuated position of FIG. 15A. [Figure 16B] 16B shows a cross-sectional view of a portion of the forceps of FIG. 1A taken along line 16B-16B' of FIG. 15B, with the trigger in the actuated position of FIG. 15B. [Figure 17A] FIG. 1B shows a side view of the forceps subassembly of FIG. 1A held by hand during assembly, with some parts shown in phantom. [Figure 17B] FIG. 17B shows a side view of the subassembly of FIG. 17A inserted into a first housing portion, with some parts shown in phantom. [Figure 17C] 17C shows a side view of the subassembly and housing of FIG. 17B shown in solid lines. [Figure 17D] FIG. 17D shows a proximal isometric view of the subassembly and housing of FIG. 17C. [Figure 18] 1B illustrates a method of assembling a medical device, such as the forceps of FIG. 1A. [Figure 19A] 1B shows the distal end of the forceps 1000 of FIG. 1A, including the wire harness routing. [Figure 19B] 19A shows a portion of the forceps 1000 of FIG. 1A, including the wire harness routing of FIG. [Figure 20A]1 illustrates an isometric view of a portion of a forceps in a closed position. [Figure 20B] 1 illustrates an isometric view of a portion of a forceps in a partially open position. [Figure 20C] 1 illustrates an isometric view of a portion of a forceps in an open position. [Figure 21] FIG. 2 illustrates a side view of a portion of a forceps in an open position. [Figure 22] FIG. 2 illustrates a top view of a portion of a forceps in an open position. [Diagram 23] 1 shows an isometric view of a portion of a forceps. [Figure 24] FIG. 2 illustrates a side view of a portion of a forceps in an open position. [Diagram 25] FIG. 2 shows a side isometric view of a portion of a forceps. [Figure 26A] 1 shows a side view of a portion of a forceps with the inner and outer shafts shown in phantom and the blades retracted. [Figure 26B] 1 shows a side view of a portion of a forceps with the inner and outer shafts shown in phantom and the blades extended. [Figure 27] 1 shows an isometric view of a portion of a forceps with the inner and outer shafts shown in phantom and the jaws removed. [Figure 28] 1 shows an isometric view of a portion of a forceps, with the inner and outer shafts shown in phantom. [Figure 29A] 1 shows an isometric view of a portion of a forceps, with the inner and outer shafts shown in phantom. [Figure 29B] 1 shows an isometric view of a portion of a forceps, with the inner and outer shafts shown in phantom. [Figure 29C] 1 shows an isometric view of a portion of a forceps, with the inner and outer shafts shown in phantom. [Figure 30A] 1 shows an isometric view of a portion of a forceps with an inner shaft in an extended position. [Figure 30B] 1 shows an isometric view of a portion of a forceps with the inner shaft in a retracted position. [Figure 30C] FIG. 13 shows an end view of the guide plug of the forceps. [Figure 31A]FIG. 13 shows an end view of the guide plug of the forceps. [Figure 31B] FIG. 13 shows an end view of the guide plug of the forceps. [Figure 31C] FIG. 13 shows an end view of the guide plug of the forceps. [Figure 32A] 1 shows a side view of a portion of a forceps. [Figure 32B] 1 shows a perspective view of a portion of a forceps. [Figure 33A] 1 shows a side view of a portion of a forceps. [Figure 33B] FIG. [Figure 34A] 1 shows a side view of a portion of a forceps. [Figure 34B] 1 shows a perspective view of a portion of a forceps. [Figure 35A] 1 shows a side view of a portion of a forceps. [Figure 35B] 1 shows a side view of a portion of a forceps. [Figure 35C] 1 shows a side view of a portion of a forceps. [Figure 36A] 1 shows a side view of a portion of a forceps. [Figure 36B] 1 shows a side view of a portion of a forceps. [Figure 36C] 1 shows a side view of a portion of a forceps. [Figure 37A] A side view of the forceps is shown. [Figure 37B] A side view of the forceps is shown. [Figure 38] 1 shows a side view of a portion of a forceps. [Figure 39A] 1 shows a side view of a portion of a forceps. [Figure 39B] 1 shows a side view of a portion of a forceps. [Figure 39C] 1 shows a side view of a portion of a forceps. [Figure 40A] 1 shows a side view of the jaw. [Figure 40B] 1 shows a side view of the jaw. [Figure 40C] 1 shows an end view of the jaws. [Figure 40D] 1 shows an isometric view of the jaws. [Figure 41A] 1 shows an isometric view of the jaws. [Figure 41B] 1 shows a side view of the jaw. [Figure 41C] 1 shows a side view of the jaw. [Figure 41D] 1 shows an end view of the jaws. [Diagram 42] FIG. 1 shows a side view of a portion of a forceps, with the inner and outer shafts shown in phantom. [Diagram 43] FIG. 1 shows a side view of a portion of a forceps, with the inner and outer shafts shown in phantom. [Diagram 44] FIG. 1 shows a side view of a portion of a forceps, with the inner and outer shafts shown in phantom. [Diagram 45] 43 shows a cross-sectional view of a portion of the forceps taken across section C1-C1 of FIG. 42. [Figure 46] 43 shows a cross-sectional view of a portion of the forceps taken across section C2-C2 of FIG. 42. [Figure 47] FIG. 1 shows a side view of a portion of a forceps, with the inner and outer shafts shown in phantom. [Figure 48] 45 shows a cross-sectional view of a portion of the forceps taken across section 45-45 of FIG. 42. [Figure 49] 46 shows a cross-sectional view of a portion of the forceps taken across section 46-46 of FIG. [Figure 50] FIG. 2 shows a side isometric view of a portion of a forceps. [Figure 51A] 1 shows an isometric end view of a portion of a forceps. [Figure 51B] 1 shows an isometric end view of a portion of a forceps. [Figure 52A] 1 shows an end isometric view of the guide tube and blade shaft. [Figure 52B] FIG. 1 shows an end view of the guide tube. [Figure 53] An exploded view of the jaw is shown. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0011] A medical device that includes a handpiece that manipulates an end effector allows a surgeon to control the end effector of the device to actuate one or more functions of the end effector. Actuation of the end effector may be facilitated by one or more actuation systems of the handpiece that may retract, extend, or rotate one or more shafts to control the movement of the end effector.

[0012] The inventors have recognized that, among other things, conventional medical devices that include a handpiece that actuates an end effector can be improved to reduce packaging space, simplify design and manufacture, improve the user experience, increase stability, and prevent damage to the forceps.

[0013] The present disclosure relates generally to medical devices, such as surgical instruments. Although the present application is described with reference to forceps, other end effectors may be used with and operated by the hand pieces described herein. In addition, other hand pieces may be connected to and controlled by the end effectors described herein. The present disclosure includes examples of hand pieces that include one or more actuation systems, examples of end effectors, and examples in which the disclosed actuation systems and end effectors may be used together in a medical device.

[0014] The forceps may include medical forceps, cutting forceps, electrosurgical forceps, or any other type of forceps. The forceps may include an end effector that is controlled by a handpiece that includes an actuation system to be one or more of rotatable, openable, closable, extendable, and capable of delivering electromagnetic energy or ultrasound. For example, jaws located at a distal end of the forceps may be actuated via one or more actuators in the handpiece of the forceps to open, close, and rotate the jaws to engage a blood vessel or other tissue. The forceps also includes an extendable and retractable blade, for example, a blade that may be extended distally between a pair of jaws to separate a first tissue from a second tissue.

[0015] FIG. 1A shows a side view of the forceps 1000 with the jaws 1012 in an open position. FIG. 1B shows a side view of the forceps 1000 with the jaws 1012 in a closed position. FIG. 2 shows an exploded view of some components of the forceps 1000 of FIG. 1A. FIG. 1A, FIG. 1B and FIG. 2 are described together. Directional descriptors such as proximal and distal are used within their normal meaning in the art. Proximal direction P and distal direction D are shown on the axes provided in FIG. 1A and FIG. 2. FIG. 2 also shows lateral directions L and L' and upward direction T and downward direction B, which are defined when the forceps 1000 is held horizontally in an upright orientation as shown in FIG. 1A with respect to a ground surface G. Opposite of the lateral directions L and L' is the medial direction, in other words, the medial direction is toward the center line, or longitudinal axis, of the forceps 1000 (FIG. 1B).

[0016] The exemplary forceps 1000 may include a hand piece 1001 at a proximal end and an end effector 1002 at a distal end. An intermediate section 1006 may extend between the hand piece 1001 and the end effector 1002 and operably couple the hand piece 1001 to the end effector 1002. Various movements of the end effector 1002 may be controlled by one or more actuation systems of the hand piece 1001. In the exemplary example, the end effector 1002 may include jaws 1012 that may be opened and closed. The end effector 1002 may be rotated along a longitudinal axis A1 (FIG. 1B) of the forceps 1000. The end effector 1002 may include a cutting blade 1032A (FIG. 2) and an electrode for applying electromagnetic energy. Not all actuation system functions and all end effector operations are required in all examples. The functions described herein may be provided in any combination.

[0017] An overview of the features of the forceps 1000 is provided in Figures 1A, 1B, 2, 3A-3E, and 4A-4C. More detailed views of an exemplary motion transmission assembly are provided in Figures 5A, 5B, 6A, 6B, 7A, 7B, 8A, and 8B. The motion transmission assembly shown transmits forces received from a user via clamping and rotation actuators (e.g., lever 1024 and rotation actuator 1030) to the jaws 1012 of the forceps 1000 to actuate the clamping and rotation of the jaws 1012.

[0018] As broadly shown in Figures 1 and 1B, along with the support of Figure 2, the forceps 1000 can include jaws 1012, a housing 1014, a lever 1024, a drive shaft 1026, an outer shaft 1028, a rotational actuator 1030, a blade assembly (blade shaft 1032 and blade 1032A in Figure 2), a trigger 1034, and an actuation button 1036. In this example, the end effector 1002, or a portion of the end effector 1002, can be one or more of open, close, rotate, extend, retract, and electromagnetically energized (e.g., electrically energized). In some examples, the energy can be radio frequency energy.

[0019] To operate the end effector 1002, a user can displace the lever 1024 proximally by applying a force F1 (FIG. 1B) to drive the jaws 1012 from an open position (FIG. 1A) to a closed position (FIG. 1B). In the example of the forceps 1000, by moving the jaws 1012 from an open position to a closed position, a user can clamp and compress tissue. The handpiece 1001 can also allow a user to rotate the end effector 1002. For example, rotating the rotational actuator 1030 rotates the end effector 1002 by rotating both the drive shaft 1026 and the outer shaft 1028 together.

[0020] In some examples, with tissue compressed between the jaws 1012, a user may press an actuation button 1036 to generate and transmit electromagnetic energy, or in some examples, ultrasound, to an end effector 1002, such as an electrode. The application of electromagnetic energy may be used to seal or otherwise affect the clamped tissue. In some examples, the electromagnetic energy may coagulate, cauterize, seal, ablate, desiccate, or cause controlled necrosis of tissue. Although example electrodes are described herein, the electromagnetic energy may be applied to any suitable electrode.

[0021] The handpiece 1001 may allow a user to extend and retract a blade 1032A attached to a distal end of a blade shaft 1032 (FIG. 2). The blade 1032A may be extended by displacing a trigger 1034 proximally. The blade 1032A may be retracted by allowing the trigger 1034 to return distally to a default position. The default position of the trigger 1034 is shown in FIG. 1A. In some examples, as described herein, the handpiece 1001 may include a feature that prevents the blade 1032A from being extended until the jaws 1012 are at least partially closed or fully closed.

[0022] The forceps 1000 can be used to perform treatment, such as a surgical procedure, on a patient. In one example, a distal portion of the forceps 1000, including the jaws 1012, can be inserted into the patient, for example, through an incision or another anatomical feature of the patient's body. A proximal portion of the forceps 1000, including the housing 1014, remains outside the incision or another anatomical feature of the body. Actuation of the lever 1024 clamps the jaws 1012 to tissue. The rotational actuator 1030 can be rotated via user input to rotate and steer the jaws 1012 at any time during the procedure. An actuation button 1036 can be actuated to supply electrical energy to the jaws 1012 to coagulate, cauterize, or seal tissue within the closed jaws 1012. A trigger 1034 can be moved to translate the blade 1032A distally to cut tissue within the jaws 1012.

[0023] In some examples, the forceps 1000 or other medical device may not include all of the features described or may include additional features and functions, and the operations may be performed in any order. The handpiece 1001 may be used with a variety of other end effectors to perform different methods.

[0024] 1A, 1B, and 2 in combination, the forceps 1000 may include various components, such as a first housing portion 1016 and a second housing portion 1018. As shown in FIG. 2, the first housing portion 1016 and the second housing portion 1018 may be mated at a mating joint 1017. The housing 1014 may include or be coupled to handle portions 1020A and 1020B, such as fixed handles configured to be held in a user's hands during use.

[0025] The housing 1014 may be a frame that provides structural support between the components of the forceps 1000. The housing 1014 is shown as housing at least a portion of an actuation system that actuates the end effector 1002 in association with the hand piece 1001. However, some or all of the actuation components need not necessarily be housed within the housing 1014. The components described herein may be completely housed within the housing 1014 through all or a portion of the range of motion of the actuation system components, partially housed through all or a portion of the range of motion of the actuation system components, or may be completely outside of the housing 1014 during all or a portion of the range of motion of the actuation system components associated with the hand piece 1001. In some examples, the housing 1014 provides a rigid structure for mounting the components, but the housing 1014 does not necessarily house the components completely, or houses only a portion of some components.

[0026] 1A, 1B, and 2, the drive shaft 1026 may extend distally through, from, or beyond the distal end of the housing 1014. The jaws 1012 may be connected to the distal end of the drive shaft 1026. The outer shaft 1028 may be a hollow tube disposed about the drive shaft 1026. The distal end of the outer shaft 1028 may be located adjacent to the jaws 1012, which may be connected to the outer shaft 1028. The distal ends of the drive shaft 1026 and the outer shaft 1028 may be rotationally locked (e.g., rotationally constrained) to the jaws 1012. The rotation actuator 1030 may be disposed about the distal end of the housing 1014. In the illustrative example, the rotational actuator 1030 is indirectly connected to the proximal end of the outer shaft 1028 by the outer hub 1060, although in some examples, the rotational actuator 1030 can be directly connected to the proximal end of the outer shaft 1028 or can integrally include features of the outer hub 1060. In some examples, the various rotational constraints described herein can be used independently. In other words, some examples can use a single rotational constraint between the rotational actuator 1030 and the jaws 1012, while in other examples, the rotational constraint can include multiple rotational constraints at different locations along the longitudinal axis A1, such as a first rotational constraint proximal to or within the hand piece 1001, and a second rotational constraint proximal to the end effector 1002 and distal to the hand piece 1001, as further described in various examples herein.

[0027] The outer shaft 1028 may extend distally beyond the rotational actuator 1030. The blade shaft 1032 may extend through the drive shaft 1026 and the outer shaft 1028. The distal end of the blade shaft 1032, including the blade 1032A, may be disposed adjacent to the jaw 1012. The proximal end of the blade shaft 1032 may be within the housing 1014.

[0028] A proximal portion 1034A (FIG. 2) of the trigger 1034 can be connected to the blade shaft 1032 within the housing 1014. A distal portion 1034B (FIG. 2) of the trigger 1034 can extend adjacent the exterior of the housing 1014 and, in some instances, nest with the lever 1024 in a default or non-actuated position shown in FIG. 1A. An actuation button 1036 can be coupled to the housing 1014. The actuation button 1036 can activate electronic circuitry within the housing 1014 and transmit electromagnetic energy through the forceps 1000 to the jaws 1012. When a user presses the actuation button 1036, the actuation button 1036 can move relative to the housing 1014. For example, when the actuation button 1036 is pressed, an electrical switch on a flexible printed circuit board affixed to the housing 1014 can be closed. Wiring and electrical components, such as a dome switch, can be actuated by the actuation button 1036, as further shown in FIG. 19. In some examples, the activation button 1036 or electronic circuitry may be outside of the housing 1014, but operably coupled to the housing 1014 and the end effector 1002. In some examples, actuation of the forceps 1000 may be accomplished by a foot or knee activated switch.

[0029] As shown in the exploded view of a portion of the forceps 1000 in FIG. 2 , the forceps 1000 includes a handpiece 1001 having components for an actuation system, an end effector 1002, an intermediate portion 1006, a jaw 1012, a housing 1014 (including a first housing portion 1016, a second housing portion 1018, handle portions 1020A and 1020B, a stabilizing flange 1021, and a recess or opening 1021A), a handle locking mechanism 1022, a lever 1024, a drive shaft 1026 (including a first horizontal slot 1069A and a second horizontal slot 1069B, an outer shaft 1028, a rotational actuator 1030, a blade shaft 1033, and a drive shaft 1034). 2, blade 1032A, trigger 1034, and actuation button 1036), first pin 1038, lever return spring 1040, coupling link 1042, second pin 1044, drive link 1046, third pin 1048, fourth pin 1050, drive shaft motion transmission body 1052 (hereinafter drive body 1052 or slider block), force limiting spring 1054, clip 1056, O-ring 1058, outer hub 1060, nose 1062, spool 1064 (e.g., a cut block or second drive shaft motion transmission body), cross pin 1066 (e.g., a blade pin), and trigger return spring 1068. The handle locking mechanism 1022 may be of the type described, for example, in U.S. patent application Ser. No. 15 / 941,205, filed Mar. 30, 2018, by Boone, entitled "Forceps Including a Pre-loaded Handle Latch," the disclosure of which is incorporated by reference in its entirety. Additionally, the components that make up the actuation system may be of the type described, for example, in U.S. patent application Ser. No. 15 / 839,218, filed Dec. 12, 2017, by Butler, entitled "Laparoscopic Forceps Assembly with An Operable Mechanism," the disclosure of which is incorporated by reference in its entirety.

[0030] As a general overview of the component interactions of the handpiece 1001 of the forceps 1000, the forceps 1000 may include a drive body 1052 that is constrained to and transmits motion to the drive shaft 1026, thereby manipulating the jaws 1012. However, in a force-limited state (e.g., position), the drive body 1052 may be slidable relative to the drive shaft 1026. Thus, the forceps 1000 may be configured to limit the force on the jaws 1012 and protect the jaws 1012 from damage when the lever 1024 is closed with the jaws 1012 stuck in an open or partially open position. An example of the jaws 1012 stuck in such a position is shown in FIG. 13C.

[0031] As further shown and described herein and elsewhere in this disclosure, the drive body 1052, in conjunction with the clip 1056, can lock the drive shaft 1026 to the rotational actuator 1030 such that the drive shaft 1026 and the outer shaft 1028 are rotationally locked (e.g., rotationally constrained) together at a proximal portion of the drive shaft 1026 and the outer shaft 1028 proximal to the rotational actuator 1030. Additionally, the forceps 1000 can include a trigger 1034, a spool 1064 proximal to the drive body 1052 and connected to the trigger 1034, and a trigger return spring 1068 disposed between the drive body 1052 and the spool 1064 to bias the blade shaft 1032 with the blade 1032A in a proximal direction, but allow the blade 1032A to move in a distal direction to effect cutting, while improving the forceps design.

[0032] Figures 3A, 3B, 3C, 3D, and 3E focus on the clamping and rotating aspects of the forceps and are described with the support of Figures 1A, 1B, and 2. Many of these components are introduced here, but are also shown and described in more detail in other figures herein. Some components related to the cutting function of the forceps in Figure 1A are not present in Figures 3A, 3B, and 3C to provide visibility of other components. Meanwhile, Figures 3A, 3B, 3C, 3D, and 3E show components that make up the actuation system of handpiece 1001, whose functions and interrelationships are described throughout this disclosure.

[0033] FIG. 3A illustrates a first partial cross-sectional view of a portion of the forceps 1000 of FIGS. 1A, 1B, and 2, in accordance with at least one example. The lever 1024, the drive shaft 1026, the drive body 1052, the force-limiting spring 1054, the clip 1056, the O-ring 1058, and the outer shaft 1028 are not shown in cross-section. FIG. 3B illustrates a second partial cross-sectional view of a portion of the forceps 1000, in accordance with at least one example. The drive shaft 1026 and the outer shaft 1028 are not shown in cross-section. FIG. 3C illustrates an enlarged exploded view of a portion of the forceps 1000 of FIG. 1A, in accordance with at least one example. FIG. 3D illustrates a third partial cross-sectional view of the forceps 1000 of FIG. 3A, in accordance with at least one example, with the drive body 1052 depicted in a rotated position. The drive body 1052, the force limiting spring 1054, the O-ring 1058, and the outer shaft 1028 are not shown in cross section. Figure 3E shows a fourth partial cross-sectional view of the forceps 1000 of Figure 3A, with the drive body 1052 depicted in the rotated position of Figure 3D, according to at least one example. The outer shaft 1028 is not shown in cross section.

[0034] 3A, 3B, 3C, 3D and 3E are described with most of the components shown in the exploded view of FIG. 3C including the housing 1014 (including the first housing portion 1016, the handle portion 1020A, and the stabilizing flange 1021), the lever 1024, the first pin 1038, the drive shaft 1026, the lever return spring 1040, the coupling link 1042 which may be in the lever recess 1025, the second pin 1044, the drive link 1046, the third pin 1048, the fourth pin 1050, the drive motion transmission assembly 1051, the drive body 1052, the force limiting spring 1054, the clip 1056, the O-ring 1058, the outer shaft 1028, the outer hub 1060, the sleeve 1061, the rotary actuator 1030, and the nose 1062. The drive shaft 1026 includes a first horizontal slot 1069A, a second horizontal slot 1069B, a first vertical slot 1070A, and a second vertical slot 1070B, which may be openings extending through the drive shaft 1026 or recesses or deformations in the drive shaft 1026. The drive body 1052 (also shown in further detail in other figures herein) may include a body portion 1072, an anchor portion 1074 (including a distal spring seat 1076 and a rotational keying slot 1078), a cylindrical portion 1080, a window portion 1082 (including a first window 1084A and a second window 1084B, see FIG. 3C), a neck portion 1086, a collar 1088 (such as a proximal collar 1088 including a drive face 1090A and a second distal spring seat 1091, see FIGS. 3B and 3C, and FIG. 5A for an enlarged view), and a passageway 1092 (e.g., a channel, bore, recess, or opening extending therethrough). The sleeve 1061 may include a flange 1094. In some examples, such as examples in which the sleeve 1061 is omitted, the outer shaft 1028 may include a flange 1094. The outer hub 1060 can include a groove 1096, an inner surface 1098, and an anti-rotation key 1100 (FIGS. 3D and 3E).

[0035] The first and second horizontal slots 1069A, 1069B can extend longitudinally along the drive shaft 1026 in an axial direction parallel to the longitudinal axis A1 (FIG. 1B). In other words, the first and second horizontal slots 1069A, 1069B can be described as extending horizontally when the drive shaft 1026 is held horizontal. In some examples, the first and second vertical slots 1070A can extend along or in a plane perpendicular to the longitudinal axis A1.

[0036] The drive shaft 1026 may include a first vertical slot 1070A on a first side and a second vertical slot 1070B on a second side (shown and described in FIGS. 3B, 3C, and further shown and described in FIGS. 5A-5C and 6A-6C). The vertical slots 1070A and 1070B may be perpendicular to the longitudinal axis A1 (FIG. 1B) of the drive shaft 1026. The first vertical slot 1070A and the second vertical slot 1070B may extend into the drive shaft 1026 from an outer surface of the drive shaft 1026. The first vertical slot 1070A and the second vertical slot 1070B may be sized to receive the clip 1056. In some examples, the clip 1056 may be raised and may be received in the drive shaft 1026 without distorting the shape of the clip 1056. In some examples, the drive shaft 1026 can have a single vertical slot 1070A or 1070B. The first and second vertical slots 1070A, 1070B can be provided as openings / apertures or as variations with or without openings through the drive shaft 1026.

[0037] As shown in the combination of Figures 3A-3E and the enlarged views of Figures 5A-5C and 6A-6C, the drive body 1052 can include a body portion 1072 and an anchor portion 1074 connected to or integrally formed with a distal end of the body portion 1072. The anchor portion 1074 can extend outwardly from an outer surface of the body portion 1072. As such, the anchor portion 1074 can include a distal spring seat 1076 on a proximal end surface of the anchor portion 1074. The distal spring seat 1076 can be connected to a distal end of the body portion 1072.

[0038] As shown in more detail in other figures herein, including some features shown in Figures 3C, 3D, and 3E and enlarged in Figure 5A, the anchor portion 1074 may include a rotational keying slot 1078. The rotational keying slot 1078 is also shown enlarged in Figure 5A. The rotational keying slot 1078 may be a horizontal slot or a slot extending parallel to the longitudinal axis A1 of the drive shaft 1026 (A1 is shown in Figure 1B). The rotational keying slot 1078 may extend to a side of the body portion 1072. In alternative examples, the drive body 1052 may have any number of rotational keying slot(s) 1078. In some examples, the rotational keying slot 1078 may be any other suitable keying interface known in the art and is not necessarily provided as a slot. The interaction between the rotational keying slot 1078 and the anti-rotation key 1100 of the outer hub 1060 is described further herein. The rotational keying slot 1078 and anti-rotation key 1100 on the outer hub 1060 can be any type of interface that limits relative rotation between the drive body 1052 and the outer hub 1060. For example, the rotational keying slot 1078 can be a protrusion instead of a slot that is received by the anti-rotation key 1100, which is a slot, recess, or groove in the outer hub 1060, to provide a relative anti-rotation feature between the drive body 1052 and the outer hub 1060.

[0039] A cylindrical portion 1080 of the drive body 1052 may be connected to or integrally formed with a distal end of the anchor portion 1074. The cylindrical portion 1080 may be sized to receive the O-ring 1058.

[0040] 3C , and as shown in more detail in other figures herein, the window portion 1082 can include a first window 1084A extending through a first side of the body portion 1072, and a second window 1084B opposite the first window 1084A and extending through a second side of the body portion 1072. Although described as a window, in some examples the window portion 1082 can be provided as a track, and such a window or track need not necessarily be bounded on all sides, and portions of the window or track may not pass completely through the body portion 1072.

[0041] As shown in Figures 3A, 3B, and 3C, with some features shown enlarged in Figure 5A, a neck portion 1086 of the drive body 1052 may be connected to a proximal end of the body portion 1072. The neck portion 1086 may have an outer diameter (e.g., a reduced diameter face) that is smaller than the outer diameter of the body portion 1072. A collar 1088 may be connected to a proximal end of the neck portion 1086. The collar 1088 may have an outer diameter that is larger than the outer diameter of the neck portion 1086 and smaller than the inner diameter of the force limiting spring 1054.

[0042] The collar 1088 may include a drive surface 1090A on a distal end face of the collar 1088 and may include a second distal spring seat 1091 at a proximal end of the collar 1088 or at a proximal end of the drive body 1052. Thus, the drive surface 1090A may be fixedly connected to or integrally molded with the proximal end of the neck portion 1086. Although the neck portion 1086 and associated flanges, such as the drive surface 1090A and the second distal spring seat 1091, are shown and described as being disposed or connected at the proximal end of the body portion 1072, they may be located elsewhere on the drive body 1052, such as along a central or distal portion of the drive body 1052, such as distal to the distal spring seat 1076.

[0043] A passageway 1092 in the drive body 1052 (FIGS. 3B, 3C) may be shaped to receive the drive shaft 1026. The passageway 1092 may be a cylindrical or non-cylindrical opening and extends through the cylindrical portion 1080, the anchor portion 1074, the body portion 1072, the window portion 1082, the neck portion 1086, and the collar 1088.

[0044] The drive shaft 1026 can extend through a passage 1092 (FIG. 3B) in the drive body 1052 such that the drive body 1052 can be disposed around at least a portion of the drive shaft 1026. The force limiting spring 1054 can be disposed on the body portion 1072 and on the window portion 1082 of the drive body 1052. A distal end of the force limiting spring 1054 can contact a distal spring seat 1076. The clip 1056 can be disposed on the window portion 1082 of the drive body 1052 and can connect to the drive shaft 1026 at the first vertical slot 1070A and the second vertical slot 1070B. Examples of clips and windows are further described in this specification, e.g., Figures 4A, 4B, 4C, 5A, 5B, 5C, 6A, 6B, 6C, 7A, 7B, 8A, 8B, 9A and 9B.

[0045] As shown in Figures 3A and 3B, with support for some features depicted in enlarged view in Figures 5A, 5B, 5C, 6A, 6B, and 6C, a proximal end of the force-limiting spring 1054 can contact a distal end face of the clip 1056. Thus, the force-limiting spring 1054 can be disposed on the drive body 1052 between a distal spring seat 1076 of the anchor portion 1074 and the clip 1056. In this arrangement, the clip 1056 is fixed to the drive shaft 1026 but can be moved longitudinally relative to the drive body 1052 within and along the window portion 1082 (Figures 4A, 4B, 4C) when a preload on the force-limiting spring 1054 is overcome by a force applied to the lever 1024. As shown enlarged in FIG. 5A, the clip support surface 1081 of the body portion 1072 can be adjacent to a proximal end of the window portion 1082, and the distal support surface 1083 of the body portion 1072 can be adjacent to a distal end of the window portion 1082. In some examples, the clip support surface 1081 and the distal support surface 1083 can act as longitudinal stops for the clip 1056 and preload the force limiting spring 1054. In one example, the preload can be in the range of 50-150 Newtons. Where possible, and in more preferred examples, the preload can be in the range of 70-90 Newtons or 135-155 Newtons, depending on the design, to improve the user experience. Unlike conventional clips, the clip 1056 can be configured to support such high preloads in combination with features of the clip 1056 that couple the clip 1056 to the drive body 1052 and the drive shaft 1026. One advantage of such a range in combination with the forceps 1000 design, including the clip 1056 design, is that such a preload can provide adequate jaw 1012 sealing pressure on tissue without requiring excessive input force F1 to actuate lever 1024. Furthermore, a single actuating jaw can provide approximately twice the sealing pressure on jaw 1012 than a dual actuating jaw when the same preload is applied to force limiting spring 1054.

[0046] To cause actuation of the jaws 1012 between the open and closed positions shown in FIGS. 1A and 1B, the lever 1024 is moved proximally or distally, which moves the drive body 1052 proximally or distally. The drive link 1046 can be operatively coupled to the housing 1014 and the drive body 1052 such that the drive link 1046 is configured to transfer a force received at the lever 1024 to a linear movement of the drive body 1052 and the drive shaft 1026 relative to the housing 1014. For example, the drive link 1046 can be connected to the drive body 1052 at a neck portion 1086. The legs 1046B of the drive link 1046, shown in FIG. 3C, can fit around the neck portion 1086. When the lever 1024 is moved proximally, the drive link 1046 can contact and press against a drive surface 1090A of the collar 1088. The location of drive surface 1090A is generally shown in the cross-sectional views of Figures 3B and 3C and in the close-up view of Figure 5 A. In contrast, when lever 1024 is moved distally, drive link 1046 may move distally and contact and press against proximal end surface 1090B of body portion 1072 of drive body 1052, also shown in the close-up view of Figure 5 A.

[0047] During a surgical procedure, carbon dioxide or other gas may be used for insufflation, introducing a pressure differential between the body cavity and the external environment. As shown in FIGS. 3A-3E, to prevent leakage, an O-ring 1058 can create a seal between the drive shaft 1026 and the outer hub 1060, such that a pressure differential is maintained (e.g., pneumatically sealed, substantially pneumatically sealed) between the body cavity in which the distal portion of the forceps 1000 is disposed and the external environment in which the proximal portion of the forceps 1000 is placed. In some examples, the O-ring 1058 can be disposed distally adjacent to the cylindrical portion 1080. Similarly, a sealing feature within the drive shaft 1026, which may be a hollow tube, can provide a similar sealing function to prevent air leakage from the body cavity to the external environment in which the proximal portion of the forceps 1000 is placed. Such a sealing feature can include a guide plug 2530 as shown in FIG. 31A.

[0048] The sleeve 1061 or the outer shaft 1028 may include a flange 1094 at a proximal end of the sleeve 1061 or the outer shaft 1028. In the example shown, the sleeve 1061 includes the flange 1094. In some examples, the flange 1094 may be welded to or formed into the sleeve 1061 or the outer shaft 1028. The flange 1094 may fit within a groove 1096 in the outer hub 1060. The flange 1094 may improve the ability to attach the sleeve 1061 or the outer shaft 1028 to the outer hub 1060. For example, the flange 1094 may fit within a groove 1096 in the outer hub 1060. The groove 1096 may form a ring on an inner surface 1098 of the outer hub 1060. In some examples, the outer hub 1060 may be molded to the outer shaft 1028. In another example, the outer hub 1060 may be overmolded to the sleeve 1061. In such a case, the groove 1096 need not necessarily be present, but the shape of the outer hub 1060 that receives the flange 1094 may be formed by overmolding the outer hub 1060 onto the flange 1094 .

[0049] 3D and 3E, the anti-rotation key 1100 may include a ridge extending from the inner surface 1098 of the outer hub 1060 into a channel in the outer hub 1060 to rotationally secure the outer hub 1060 to the drive body 1052. For example, the anti-rotation key 1100 may be sized to fit within a rotational keying slot 1078 of the anchor portion 1074. The rotational keying slot 1078 may receive the anti-rotation key 1100, and the anti-rotation key 1100 may be disposed within the rotational keying slot 1078 such that the rotational keying slot 1078 may be moved linearly in translation or longitudinally along the anti-rotation key 1100. These features are shown in further detail in FIGS. 11A and 11B.

[0050] A flange 1094 and groove 1096 or other structure may connect and lock the outer shaft 1028 to the outer hub 1060. An anti-rotation key 1100 and rotational keying slot 1078 may connect and rotationally lock the outer hub 1060 and drive body 1052. The drive shaft 1026 may also be rotationally locked to the drive body 1052 by a clip 1056. Thus, rotating the rotary actuator 1030 rotates the outer hub 1060, which rotates both the outer shaft 1028 and the drive shaft 1026. The connections between the outer hub 1060, drive body 1052, and rotary actuator 1030 are shown and described in further detail with reference to FIGS. 10A, 10B, 11A, and 11B. Alternative examples of connections between the outer hub 1060, drive body 1052, and rotary actuator 1030 are described with reference to FIG. 12.

[0051] As shown in FIG. 3C, to improve stabilization of the drive shaft 1026 while simultaneously allowing one or both of rotational and longitudinal movement, the first housing portion 1016 can include a stabilizing flange 1021 that includes a recess or opening 1021A through which the proximal end of the drive shaft 1026 can extend or pass.

[0052] To provide articulation of the lever 1024, the lever 1024 may be operatively coupled to the housing 1014 via a first pin 1038. The lever 1024 may be movable by pivoting about the first pin 1038. In this example, the first pin 1038 may be held within the housing 1014. In another example, the first pin 1038 may be held by or part of the lever 1024. As shown in FIG. 3A, the lever 1024 may be biased to a default position (FIG. 1A) by a lever return spring 1040. In this example, the lever return spring 1040 may be constrained between the housing 1014 and the lever 1024. In some examples, the lever return spring 1040 may be comprised as any suitable type of biasing element, such as a helical spring, an elastomeric component, an elastomeric band, or an elastomeric block arranged to bias the lever to the default position. Such a biasing element can be strained, for example by compression, elongation, twisting, or flexing, and resiliently return to its original, or substantially original, configuration.

[0053] In general overview, a first end of the coupling link 1042 may be connected to the lever 1024 via a second pin 1044 to transmit an input motion (e.g., input force F1) received at the lever 1024. A second end of the coupling link 1042 may be connected to a first end of a drive link 1046 via a third pin 1048. Thus, the coupling link 1042 may connect the lever 1024 to the drive link 1046. A second end of the drive link 1046 may be connected to the housing 1014 via a fourth pin 1050. The drive link 1046 may be formed as a yoke. For example, as shown in FIG. 3C, the drive link 1046 may include a base 1046A between the first and second ends of the drive link 1046. A pair of spaced apart legs 1046B can extend from a base 1046A of the drive link 1046 such that the ends of the legs 1046B form a second end of the drive link 1046 (see also FIG. 14B).

[0054] The illustrative forceps 1000 includes a drive shaft motion transmission assembly 1051 coupled to a housing 1014. The drive shaft motion transmission assembly 1051 may include a drive body 1052, which functions to transmit an input force F1 from the lever 1024 to the drive shaft 1026 to retract or extend the drive shaft 1026 (e.g., to open or close the jaws 1012).

[0055] In addition to transmitting the input force F1 from the lever 1024 to the drive shaft 1026, in some examples, and as shown in the exemplary forceps 1000, the drive shaft motion transmission assembly 1051, including the drive body 1052, may also transmit rotational motion from the rotary actuator 1030 through the outer hub 1060 to both the drive shaft 1026 and the outer shaft 1028. However, not all examples of the drive body 1052 require the drive body 1052 to transmit both longitudinal and rotational motion to the drive shaft 1026. In some examples, the drive body 1052 may be configured to only transmit either longitudinal or rotational motion to the drive shaft 1026 via the drive body 1052. For example, some medical devices may use the extension or retraction features of the forceps 1000 but not rotate, and conversely, another medical device may use a rotation feature without an extension or retraction feature.

[0056] In the example drive shaft motion transmission assembly 1051, the drive body 1052 can be disposed about the drive shaft 1026. The drive shaft 1026 can extend through a passageway 1092 in the drive body 1052 (FIGS. 3B, 3C). In some examples, the passageway 1092 can be formed as a central bore, but in some examples, the passageway 1092 need not be central and / or need not be provided as a circular bore. In other examples, the passageway 1092 can be square, polygonal, irregular, or can include notches. In some examples, the passageway 1092 can include a channel. In some examples, the passageway 1092 may not surround the drive shaft 1026.

[0057] The drive body 1052 may be disposed distal to and coupled to the lever 1024. In this example, the drive body 1052 is indirectly coupled to the lever 1024 via a series of linkages. The drive body 1052 is connected to the lever 1024 via a drive link 1046 and may receive an input force F1 from the lever 1024 to retract or extend the drive shaft 1026 relative to the housing 1014 and outer shaft 1028 (thereby opening and closing the jaws 1012). The drive body 1052 may be disposed within a yoke formed by the drive link 1046 and receives an input from the drive link 1046.

[0058] The drive shaft motion transmission assembly 1051 may include a force limiting spring 1054 and a clip 1056. The force limiting spring 1054 may be disposed about the drive body 1052. The clip 1056 may be disposed adjacent an end of the force limiting spring 1054 on the drive body 1052. The clip 1056 may be secured to the drive shaft 1026. In some examples, the force limiting spring 1054 may be any suitable type of biasing element, such as an elastomeric component, elastomeric band, or elastomeric block, capable of elastically deforming to return to its original state or substantially its original state. In some examples, the clip 1056 may be inserted into the drive shaft 1026 via one or more slots (such as vertical slots 1070A and 1070B). In some examples, the clip may be flat, while in other examples, the clip may be non-planar or have an irregular, non-flat surface.

[0059] In some examples, the drive shaft motion transmission assembly 1051 can include an outer hub 1060 that can be connected to the drive body 1052. The outer hub 1060 can include an inner surface 1098 within which the drive body 1052, the force limiting spring 1054, and the clip 1056 (FIGS. 3A, 3C) can translate longitudinally together.

[0060] The rotary actuator 1030 may be disposed about and connected to the outer hub 1060. The rotary actuator 1030 may be rotationally constrained to the outer hub 1060 and axially constrained to the outer hub 1060. The rotary actuator 1030 may also be axially constrained to the housing 1014. The nose 1062 may be connected to a distal end of the outer hub 1060, for example, by a snap fit, adhesive, or threaded connection. The drive shaft 1026 and the outer shaft 1028 may extend through and from the nose 1062. In some examples, the rotary actuator 1030 and / or the nose 1062 may be omitted and the outer hub 1060 functions as the rotary actuator 1030 and / or the nose 1062 and receives rotational input directly from the user. In some examples, instead of the nose 1062 being connected to the distal end of the outer hub 1060, the nose 1062 may be directly connected to the rotary actuator 1030, for example, by a snap fit, adhesive, or threaded connection.

[0061] In the example of FIG. 3A , axial retention of the rotary actuator 1030 to the housing 1014 may be provided by axially constraining the rotary actuator 1030 between the housing 1014 and the nose 1062. A connection between a first snap fit connector 1060C on the outer hub 1060 and a second snap fit connector 1062C on the nose 1062 may constrain the rotary actuator 1030 from moving in a distal direction. The first and second snap fit connectors are shown by way of example only and any type of snap fit connector or alternative may be provided. In this arrangement, the outer hub 1060 may be axially constrained to the housing 1014 by the proximal and distal flanges 1060A, 1060B of the outer hub 1060, which may be captured by surfaces of the housing 1014 that interface with the proximal and distal flanges 1060A, 1060B. Additionally, because the nose 1062 is axially constrained relative to the outer hub 1060, the rotary actuator 1030 may also be axially constrained relative to the outer hub 1060, the nose 1062, and the housing 1014 by being captured between the nose 1062 and the housing 1014. In other words, the nose 1062 axially engages the outer hub 1060 to provide axial retention of both the nose 1062 and the rotary actuator 1030.

[0062] FIG. 4A illustrates a partial cross-sectional view of the forceps 1000 of FIG. 1A with the lever 1024 in a distal position (e.g., a non-actuated position), according to at least one example. FIG. 4B illustrates a partial cross-sectional view of the forceps 1000 of FIG. 1A with the lever 1024 moved proximally (e.g., to an actuated position, one of a plurality of actuated positions, or a user position), according to at least one example. FIG. 4C illustrates a partial cross-sectional view of the forceps 1000 of FIG. 1A with the lever 1024 moved further proximally (e.g., to a further actuated position, which in some examples may be a fully actuated position, in which case a force-limiting or overtravel state), according to at least one example. It should be noted that the force-limiting state is a position of the drive body 1052 that occurs when the force applied to the lever 1024 and transmitted to the drive body 1052 exceeds a predetermined force based on the preload of the force-limiting spring 1054. Force limiting may occur in another actuated position once the predetermined force is exceeded.

[0063] 4A, 4B, and 4C taken together provide a general illustration of how the drive body 1052, force limiting spring 1054, and clip 1056 can function on the drive shaft 1026 in response to the lever 1024 providing an input to the linkage between the lever 1024 and the drive body 1052. The components of the forceps 1000 shown in FIGS. 4A, 4B, and 4C include a housing 1014 with a stabilizing flange 1021, a lever 1024, a drive shaft 1026, a trigger 1034, a coupling link 1042, a drive link 1046, a drive body 1052, a force limiting spring 1054, a clip 1056, an outer hub 1060, a spool 1064, a cross pin 1066, and a trigger return spring 1068. The drive shaft 1026 may include a first horizontal slot 1069A, a second horizontal slot 1069B, a first vertical slot 1070A, and a second vertical slot 1070B (hidden here but visible in FIG. 3C). The drive body 1052 includes a body portion 1072, an anchor portion 1074 (including a distal spring seat 1076), a window portion 1082 (including a first window 1084A and a second window 1084B), a neck portion 1086, and a collar 1088 (including a drive face 1090A and a second distal spring seat 1091, also shown in FIG. 3C and enlarged in FIG. 5A). The outer hub 1060 includes an inner surface 1098. The spool 1064 may include a proximal trigger return spring seat 1101. The spool 1064 is shown as one example of a motion transmitter designed to transmit motion received from an actuator to a shaft (e.g., received from the trigger 1034 and transmitted to the blade shaft 1032). In other examples, the motion transmitter within the present disclosure need not be in the form of a spool, such as an example in which the spool 1064 need not be rotatable.

[0064] As shown in FIG. 4A , when the lever 1024 is in a distal position (e.g., a default position, an open position of the jaws 1012), the drive body 1052 is disposed within a channel formed by an inner surface 1098 of the outer hub 1060. A majority of a body portion 1072 of the drive body 1052 is within the channel of the outer hub 1060. The drive shaft 1026 is in a first position relative to the housing 1014, is not pulled in a proximal direction (e.g., an unactuated position, a non-retracted position) by the clip 1056, and is within the opening of the stabilizing flange 1021. As a result, the jaws 1012 are in an open position, as shown in FIG. 1A .

[0065] As shown in FIG. 4B, when the lever 1024 is moved proximally, it pulls the lower end of the drive link 1046 proximally relative to the housing 1014 via the coupling link 1042. The drive link 1046 is connected to the drive body 1052 at the neck portion 1086 and pushes against the drive face 1090A of the collar 1088, causing the drive body 1052 to move longitudinally proximally relative to the housing 1014 (see FIG. 5A for a close-up view of the drive body 1052). As a result, a majority of the body portion 1072, including the window portion 1082 of the drive body 1052, moves out of the channel in the outer hub 1060. As the drive body 1052 is pulled proximally, the force limiting spring 1054 and the clip 1056 move with the drive body 1052 at the same position relative to the drive body 1052.

[0066] In other words, the distal spring seat 1076 drives the force-limiting spring 1054, which drives the clip 1056 together with the drive body 1052. When the driving force provided by the drive link 1046 is less than the preload force of the force-limiting spring 1054, the force-limiting spring 1054 acts like a rigid body and the ends of the force-limiting spring 1054 move together. Thus, the drive body 1052 moves proximally relative to the housing 1014 and the clip 1056 moves proximally relative to the housing 1014. Because the clip 1056 is longitudinally locked to the drive shaft 1026 at the first vertical slot 1070A and the second vertical slot 1070B, the drive shaft 1026 also moves proximally relative to the housing 1014. As the drive shaft 1026 moves proximally (e.g., retracts), the end effector 1002 becomes actuated. In this example, actuating the end effector 1002 includes causing the jaws 1012 to begin closing.

[0067] 4B , the lever 1024 may be closed by a user input to close the jaws 1012. Movement of the lever 1024 causes movement of the drive body 1052. Closing the lever 1024 causes the coupling link 1042 to pull the drive link 1046 proximally relative to the housing 1014, which causes the drive body 1052 to translate longitudinally in the proximal direction. Moving the drive body 1052 proximally causes the drive shaft 1026 to translate longitudinally in the proximal direction because the drive body 1052 and drive shaft 1026 are connected via the clip 1056. As a result of the movement of the drive shaft 1026, a mechanism on the jaws 1012 is actuated, closing the jaws 1012. As shown in the illustrative example, the drive link 1046 drives the drive body 1052 longitudinally, but the drive body 1052 is still free to rotate inside the yoke of the drive link 1046 and can rotate relative to the drive link 1046. However, in some examples, the rotational aspect may be omitted.

[0068] In the illustrative example, at any time during use, regardless of whether the jaws 1012 are open or closed, the jaws 1012 may be rotated. For example, rotation of the rotational actuator 1030 rotates the outer hub 1060, which advantageously transfers rotational motion to rotate the outer shaft 1028 and the drive body 1052. Because the drive body 1052 is locked (e.g., constrained) to the drive shaft 1026 via a clip 1056, the drive shaft 1026 may also be rotated with the outer shaft 1028. Thus, the outer shaft 1028 and the drive shaft 1026 may be rotationally locked (e.g., rotationally constrained) together at a proximal end of the forceps 1000, and, as described further herein, the outer shaft 1028 and the drive shaft 1026 may also be rotationally locked or constrained together at a distal end of the forceps 1000 (e.g., by a guide 2014 shown in the forceps 2000 of FIG. 20A, as described further herein).

[0069] Additionally, the first horizontal slot 1069A and the second horizontal slot 1069B of the drive shaft 1026 may engage and rotate with the cross pin 1066 as the drive shaft 1026 rotates, causing the blade shaft 1032 and the spool 1064 to rotate. Thus, the drive shaft 1026 and the blade assembly (1032, 1032A) may be rotationally constrained (e.g., fixed, locked together) at the proximal end of the forceps 1000 via the cross pin 1066 (FIGS. 2, 4A). In other words, the blade assembly (1032, 1032A) may be rotationally constrained to the drive shaft 1026 at a longitudinal position along the longitudinal axis A1 (FIG. 1B) that is proximal to the jaws 1012 and proximal to the drive body 1052.

[0070] When actuation is complete, the lever return spring 1040 can act on the lever 1024 to return (e.g., bias) the lever 1024 to a default position (e.g., distal position) to return the jaws 1012 to the unactuated state of FIG. 4A. Because the lever 1024 is coupled to the drive shaft 1026 by a series of linkages, described herein with reference to at least FIGS. 15A and 15B, the lever return spring 1040 also returns the drive shaft 1026, thereby returning the jaws 1012 to the default position (FIG. 15A), which in this example is the open position. As shown in FIG. 4C, the jaws 1012 may get caught or caught on an anatomical feature of the patient or another medical device as the lever 1024 is moved proximally. In such a situation, the jaws 1012 may not be able to close completely. However, the drive motion transmission assembly 1051 of the forceps 1000 includes a force limiting feature to prevent the drive shaft 1026 from retracting to the point where additional input force F1 from the user would be transmitted to the jaws 1012, thereby damaging the jaws 1012. The forceps 1000 may enable a force limited state (e.g., an overtravel state) to be achieved if the lever 1024 is moved proximally and the jaws 1012 sticks in an open or partially open position and the user continues to apply force to the lever 1024.

[0071] To prevent damage to the jaws 1012, the force-limiting spring 1054 may be configured to absorb excess force applied to the lever 1024 instead of transmitting the excess force to the jaws. For example, the force-limiting spring 1054 may extend from a first end portion to a second end portion and may be in a preloaded state between a distal spring seat 1076 and a distal end face 1105 of the clip 1056. The force-limiting spring 1054 may urge the clip 1056 in a proximal direction such that the clip 1056 contacts and is supported by a clip support surface (e.g., clip support surface 1081, FIG. 5A) of the body portion 1072 adjacent a proximal end of the window portion 1082. The clip support surface (1081, FIG. 5A) may act as a proximal stop for the clip 1056. With the force-limiting spring 1054 in a compressed state, the distal spring seat 1076 can be configured to receive a first spring force from a distal end portion of the force-limiting spring 1054 and the clip 1056 can be configured to receive a second spring force from a proximal end portion of the force-limiting spring 1054. The drive body 1052 can include a clip support surface 1081 that is configured to transmit the first force to a second surface (e.g., the proximal end surface 1103) of the clip 1056 when the force-limiting spring 1054 drives the clip 1056 against the clip support surface 1081 under a load, such as a preload.

[0072] 4C, in an example of force limiting, the lever 1024 is moved by the user to a proximal position, exerting a force on the drive link 1046, pulling the lower end of the drive link 1046 further in a proximal direction, but preventing the jaws 1012 from closing further. As a result, the drive link 1046 exerts a greater force on the drive surface 1090A of the collar 1088, causing the drive body 1052 to move further proximally relative to the housing 1014, which in turn moves further proximally away from the inner surface 1098 that forms the passageway 1098A (FIG. 3C) of the outer hub 1060. The outer hub 1060 may be restrained from axial movement relative to the housing 1014 by the fact that the proximal housing flange 1060a and the distal flange 1060B of the outer hub 1060 may be captured by a portion of the housing 1014. As the drive body 1052 moves proximally, a distal spring seat 1076 of the anchor portion 1074 of the drive body 1052 presses against a distal end of the force-limiting spring 1054. However, the jaws 1012 cannot close any further, so the drive shaft 1026 cannot move proximally with the drive body 1052. Furthermore, because the clip 1056 is locked to the drive shaft 1026, the clip 1056 cannot move proximally relative to the housing 1014. Thus, the drive body 1052 moves proximally relative to the clip 1056 and the drive shaft 1026 by sliding (e.g., linearly, longitudinally, or translating) proximally relative to the clip 1056.

[0073] The clip 1056, by remaining fixed relative to the drive shaft 1026, effectively moves distally relative to the drive body 1052 within the first window 1084A and second window 1084B of the window portion 1082. Thus, the force limiting spring 1054 becomes more compressed between the distal spring seat 1076 and the distal end face of the clip 1056 when the force applied to the drive link 1046 is greater than the preload of the force limiting spring 1054. A user may feel this force limiting feature as an increase in the force on the lever 1024 due to the additional compression of the force limiting spring 1054 in the preloaded state, but the lever 1024 is still able to move, even though it is no longer transmitting motion to the drive shaft.

[0074] In other words, the lever 1024 can be moved fully to a proximal position, causing the drive body 1052 to move proximally within the housing 1014 until the drive shaft 1026 moves. At the same time, the jaws 1012 can be locked in an open position (e.g., caught by something) to prevent the drive shaft 1026 from moving even if the lever 1024 is moved proximally. Because the drive shaft 1026 cannot move proximally within the housing 1014, the clip 1056 cannot move proximally relative to the housing 1014. However, because the clip 1056 can slide within the window portion 1082, the drive body 1052 can move (e.g., slide, translate) proximally relative to the clip 1056, changing the position of the clip 1056 within the window portion 1082. As the drive body 1052 moves relative to the clip 1056, the force-limiting spring 1054 compresses and absorbs the force applied to the lever 1024. Because moving the drive shaft 1026 closes the jaws 1012, the ability to prevent the drive shaft 1026 from moving when the jaws 1012 are unable to close prevents the jaws 1012 from being damaged when a user does not realize that the jaws 1012 are stuck open and continues to pull the lever 1024 proximally to close the jaws 1012.

[0075] In addition to the clamping system shown and described in Figures 4A, 4B, and 4C, Figures 4A, 4B, and 4C also show components that can be used to actuate another system, such as, but not limited to, a cutting system for actuating a blade assembly (e.g., blade shaft 1032, Figure 3C). Additional aspects of the cutting system are further described throughout this disclosure, and in particular in Figures 15A, 15B, 16A, and 16B.

[0076] As shown in the illustrative examples of Figures 4A, 4B and 4C, the spool 1064 may be disposed about the proximal end of the drive shaft 1026 proximal to the drive body 1052 and connected to the proximal end of the blade shaft 1032 via a cross pin 1066. Thus, the blade assembly (1032, 1032A) is attached to the proximal end of the drive shaft 1026 via the cross pin 1066 extending through the first horizontal slot 1069A and the second horizontal slot 1069B. The spool 1064 may be within the housing 1014 distal to the stabilizing flange 1021. The spool 1064 may be axisymmetric and may be longitudinally movable relative to the drive shaft 1026. An alternative example is that if the drive shaft 1026 and the blade shaft 1032 do not need to rotate, the spool 1064 may be a non-spool shaped body.

[0077] The trigger 1034 may be connected to a spool 1064. The proximal end of the trigger 1034 may include one or more legs, in this example, two legs forming a yoke, which may fit around and be connected to the spool 1064. The spool 1064 may rotate relative to the trigger 1034 to rotate the drive shaft 1026. The trigger return spring 1068 may be a helical compression spring disposed on the drive shaft 1026 between the distal end of the spool 1064 and the proximal end of the drive body 1052. The trigger return spring 1068 may be assembled by loading the trigger return spring 1068 onto the drive shaft 1026 and then placing the spool 1064 onto the drive shaft 1026 to connect the trigger 1034 to the blade shaft 1032. In some examples, the trigger return spring 1068 can be any suitable biasing element, such as an elastomeric component, elastomeric band, or elastomeric block, that can be tensioned and elastically return to its original, or substantially original, form.

[0078] To facilitate extension and retraction of the blade shaft 1032, the cross pin 1066 may travel within a first horizontal slot 1069A and a second horizontal slot 1069B of the drive shaft 1026. In some examples, the dimensions of the first horizontal slot 1069A and the second horizontal slot 1069B may be such that they act as guide rails for the cross pin 1066 to control the longitudinal reciprocating motion of the spool 1064. In such examples, the spool 1064 may be guided by the drive shaft 1026. The first horizontal slot 1069A may extend on a first side of the drive shaft 1026 and the second horizontal slot 1069B may extend on a second side of the drive shaft 1026 opposite or opposite the first horizontal slot 1069A. The first horizontal slot 1069A and the second horizontal slot 1069B are near a proximal end of the drive shaft 1026. Thus, the cross pin 1066 may extend through the spool 1064, the first horizontal slot 1069A of the drive shaft 1026, the blade shaft 1032, and the second horizontal slot 1069B of the drive shaft 1026. The second arm 1034D is hidden in FIGS. 4A, 4B, and 4C. The spool 1064 may include a proximal trigger return spring seat 1101 at a distal end of the spool 1064. Thus, the trigger return spring 1068 may be disposed on the drive shaft 1026 between the proximal end of the drive body 1052, or the second distal spring seat 1091, and the distal end of the spool 1064, or the proximal trigger return spring seat 1101. In an alternative example, the second passage 1064A (FIG. 2) in the spool 1064 may ride on the drive shaft 1026 and be guided to move longitudinally along the drive shaft 1026.

[0079] The cutting system is further shown and described in Figures 15A, 15B, 16A and 16B, but as a general overview, the cutting system may be operated as follows: Compressing the distal end of the trigger 1034 may cause the proximal end of the trigger 1034 to move distally relative to the housing 1014, which may cause the spool 1064 to move distally. The spool 1064 may press against the proximal end of the trigger return spring 1068. The preload of the trigger return spring 1068 may be overcome, causing the trigger return spring 1068 to compress. A spool 1064 connected to the blade shaft 1032 by a cross pin 1066 may move the blade shaft 1032 longitudinally distally via the cross pin 1066 moving along or within a first horizontal slot 1069A and a second horizontal slot 1069B of the drive shaft 1026, causing the blade 1032A (FIG. 2) to protrude from the distal end of the drive shaft 1026. When the trigger 1034 is not compressed, the trigger return spring 1068 can expand, pushing the spool 1064 and the blade shaft 1032 proximally to a position where the blade 1032A (FIG. 2) does not protrude from the drive shaft 1026.

[0080] FIG. 5A is an isometric view of an exemplary drive shaft motion transmission assembly 1051 that may be used in the forceps 1000 of FIG. 1A, including a drive body 1052, a force limiting spring 1054, a clip 1056, and a drive shaft 1026. FIG. 5B is an isometric view of the drive body 1052 and clip 1056 on the drive shaft 1026, with the force limiting spring 1054 in cross section. FIG. 5C is an exploded view of the drive body 1052, clip 1056, and drive shaft 1026. FIGS. 5A, 5B, and 5C are discussed together. The motion transmission assembly 1051 functions to transmit a force input F1 applied by a user at the lever 1024 (FIG. 1B) and / or a rotational input R1 applied by a user at the rotational actuator 1030 to the end effector 1002 (FIG. 1B).

[0081] 5A and 5B example motion transmission assembly 1051 is described as follows: Drive shaft 1026 can include a first vertical slot 1070A and a second vertical slot 1070B. Drive body 1052 can include a body portion 1072, an anchor portion 1074 (including a distal spring seat 1076), and a window portion 1082 (including a first window 1084A and a second window 1084B), a surface that interfaces with drive link 1046 and includes a collar 1088, a neck portion 1086, and a distal collar 1089 (distal face, distal face facing proximally, etc.). The clip 1056 may include a clip body 1102 having a proximal end surface 1103 and a distal end surface 1105 (e.g., a proximal spring seat 1104), a clip slot 1106, clip notches 1108A and 1108B (including a first clip notch 1108A and a second clip notch 1108B). The window portion 1082 may further include retention ribs 1110A and 1110B (including a first retention rib 1110A and a second retention rib 1110B) and window notches 1112A and 1112B (including a first window notch 1112A and a second window notch 1112B). The drive shaft 1026, drive body 1052, force limiting spring 1054, and clip 1056 may have the same structure and function as described with respect to FIGS. 1A-4C.

[0082] The clip 1056 may have a clip body 1102 with a proximal end face 1103 opposite a distal end face 1105. The distal end face 1105 of the clip body 1102 may include a proximal spring seat 1104 for supporting the force limiting spring 1054. The clip slot 1106 may be a slot extending into the clip body 1102 from a bottom of the clip body 1102. The clip slot 1106 may have a width approximately equal to or slightly greater than the length of the drive shaft 1026 from the first vertical slot 1070A to the second vertical slot 1070B. In another example where the clip 1056 is flexible, the clip slot 1106 may have a width slightly less than the length of the drive shaft 1026 from the first vertical slot 1070A to the second vertical slot 1070B. The clip notches 1108A and 1108B can extend from the clip slot 1106 into the clip body 1102. The first clip notch 1108A can extend into the clip body 1102 from a first side of the clip slot 1106 at the top of the clip slot 1106, and the second clip notch 1108B can extend into the clip body 1102 from a second side of the clip slot 1106 at the top of the clip slot 1106. Thus, the second clip notch 1108B can extend into the clip body 1102 from the clip slot 1106 opposite the first clip notch 1108A.

[0083] The window portion 1082 may include a first window 1084A extending through a first side of the body portion 1072 and a second window 1084B extending through a second side of the body portion 1072 opposite the first window 1084A. A first retention rib 1110A may extend from a top of the body portion 1072 into the first window 1084A. The first retention rib 1110A may extend from an upper portion of the top of the body portion 1072 such that the first retention rib 1110A forms a first lip on the top of the body portion 1072. A second retention rib 1110B may extend from a top of the body portion 1072 into the second window 1084B. The second retention rib 1110B can extend from an upper portion of the top of the body portion 1072 such that the second retention rib 1110B forms a second lip on the top of the body portion 1072. The first window notch 1112A can be included as part of the first window 1084A at the distal end of the first retention rib 1110A. The second window notch 1112B is included as part of the second window 1084B at the distal end of the second retention rib 1110B. In alternative examples, the first window notch 1112A and the second window notch 1112B can be located anywhere along the first retention rib 1110A and the second retention rib 1110B, respectively. In a potentially beneficial example, the placement of the first and second window notches 1112A and 1112B may be far enough distally apart so that the clip 1056 never aligns with the window notches 1112A and 1112B when assembled, even when the force-limiting spring 1054 is compressed. Preventing the clip 1056 from aligning with the window notches 1112A and 1112B prevents the clip 1056 from moving out of the window notches 1112A and 1112B.

[0084] When the drive body 1052 is on the drive shaft 1026, the clip 1056 may be disposed on the window portion 1082 of the drive body 1052. The clip slot 1106 may fit around the drive body 1052 at the window portion 1082 and around the drive shaft 1026 at the first vertical slot 1070A and the second vertical slot 1070B such that the clip 1056 is received within and by the first vertical slot 1070A and the second vertical slot 1070B of the drive shaft 1026. A proximal end of the force limiting spring 1054 may contact the proximal spring seat 1104 of the clip 1056. A distal end of the force limiting spring 1054 may contact the distal spring seat 1076. The distance between the proximal spring seat 1104 and the distal spring seat 1076 is less than the length of the force-limiting spring 1054, compressing and preloading the force-limiting spring 1054. The first clip notch 1108A can fit around the first retention rib 1110A. The second clip notch 1108B can fit around the second retention rib 1110B. The clip 1056 can move longitudinally within the first window 1084A and the second window 1084B in the window portion 1082 and along the first retention rib 1110A and the second retention rib 1110B.

[0085] A first vertical slot 1070A and a second vertical slot 1070B on the drive shaft 1026 longitudinally and rotationally lock the clip 1056 to the drive shaft 1026. Clip notches 1108A and 1108B and retention ribs 1110A and 1110B may mate together to retain the clip 1056 to both the drive body 1052 and the drive shaft 1026, preventing the clip 1056 from backing out of the first vertical slot 1070A, the second vertical slot 1070B, and the window portion 1082, and rotationally locking the clip 1056 to the drive body 1052. However, as described herein, in some instances (e.g., in a force-limiting state), the drive body 1052 can still move longitudinally relative to the clip 1056, such that the clip 1056 moves longitudinally relative to the drive body 1052 within the first 1084A and second 1084B windows and along the retaining ribs 1110A and 1110B. As a result, the drive body 1052 can move longitudinally relative to the drive shaft 1026. The clip 1056 prevents the drive body 1052 from backing out or popping out of the drive body 1052 and drive shaft 1026, while the drive body 1052 moves longitudinally relative to the clip 1056 and drive shaft 1026. In the assembled state, the clip 1056 may be misaligned with the window notches 1112A and 1112B, but may be aligned with the first and second vertical slots 1070A and 1070B (FIG. 5C).

[0086] In this arrangement, the clip 1056 may be fixed to the drive shaft 1026 and slidably coupled to the drive body 1052. Rotational motion may be transferred from the drive body 1052 through the clip 1056 to the drive shaft 1026, and linear motion may be transferred from the drive body 1052, through the force limiting spring 1054, to the clip 1056, and indirectly from the clip 1056 to the drive shaft 1026, causing the drive shaft 1026 to translate.

[0087] In other words, the clip 1056 may be coupled to the drive body 1052 and the drive shaft 1026 to rotationally secure the drive body 1052 to the drive shaft 1026. The drive body 1052 may be configured to transfer rotational input received from the rotational actuator 1030 to rotational movement of the clip 1056, and the clip 1056 may be configured to transfer rotational movement of the clip 1056 to rotational movement of the drive shaft 1026.

[0088] As shown in FIG. 5A, the input surface for receiving input from the drive link 1046 (FIGS. 3A, 3B, 3C) can include a collar 1088 (e.g., a first surface), a neck portion 1086 (e.g., a smaller diameter surface), and a distal collar 1089 (e.g., a distal surface). The collar 1088, the neck portion 1086, and the distal collar 1089 can form a spool portion of the drive body 1052. In some examples, the spool portion (e.g., 1088, 1086, and 1089) can be an axisymmetric spool portion. In some examples, the distal surface 1088B of the proximal collar 1088 and the proximal surface 1089A of the distal collar 1089 are flat. In some examples, the distal surface 1088B of the proximal collar 1088 and the proximal surface 1089A of the distal collar 1089 are parallel. In some examples, the spool portion allows for rotational displacement of the drive body 1052 relative to the drive link 1046.

[0089] FIG. 6A is a partial exploded view of a motion transmission assembly 1051 including a first example of a drive body 1052 and a first example of a clip 1056, with the drive body 1052 presented on a drive shaft 1026. FIG. 6B is an isometric view of the first example of a drive body 1052 and the first example of a clip 1056, depicting a compressed force-limiting spring 1054 and the clip 1056 assembled on the drive shaft 1026 along an insertion direction I1. FIG. 6C is a diagram of the first example of a drive body 1052 and the first example of a clip 1056 in a force-limiting state (e.g., an overtravel position). FIGS. 6A, 6B, and 6C are discussed together to explain how the drive body 1052, the force-limiting spring 1054, and the clip 1056 are assembled on the drive shaft 1026.

[0090] The drive shaft 1026 may include a first vertical slot 1070A and a second vertical slot 1070B. The drive body 1052 may include a body portion 1072, an anchor portion 1074, and a window portion 1082 (including a first window 1084A and a second window 1084B). The clip 1056 may include a clip body 1102, a proximal spring seat 1104, a clip slot 1106, clip notches 1108A and 1108B (including a first clip notch 1108A and a second clip notch 1108B). The window portion 1082 may further include retention ribs 1110A and 1110B (including a first retention rib 1110A and a second retention rib 1110B) and window notches 1112A and 1112B (including a first window notch 1112A and a second window notch 1112B). The drive shaft 1026, drive body 1052, force limiting spring 1054, and clip 1056 may have the same structure and function as described with respect to Figures 1A-5C.

[0091] To assemble the drive body 1052, the force limiting spring 1054, and the clip 1056 to the drive shaft 1026, first the drive body 1052 may be disposed on the drive shaft 1026. Second, the force limiting spring 1054 may be disposed on the drive body 1052 around the body portion 1072 and the window portion 1082 of the drive body 1052. Third, the force limiting spring 1054 may be slid onto the drive body 1052 from the drive shaft 1026 and the proximal end of the drive body 1052. Fourth, the force limiting spring 1054 may be compressed against the anchor portion 1074 such that the force limiting spring 1054 is not disposed around the window notches 1112A and 1112B, as shown in FIG. The drive body 1052 may be placed on the drive shaft 1026 such that the first and second vertical slots 1070A and 1070B of the drive shaft 1026 are aligned with the window notches 1112A and 1112B of the window portion 1082 of the drive body 1052. The first and second vertical slots 1070A and 1070B are visible through the first and second windows 1084A and 1084B when the first and second vertical slots 1070A and 1070B are aligned with the window portion 1082. The clip 1056 may then be placed on the window portion 1082 of the drive body 1052 at the window notches 1112A and 1112B such that the clip 1056 also extends through the first and second vertical slots 1070A and 1070B of the drive shaft 1026, as shown in FIG. In this assembly method, the clip 1056 does not have to bend, stress or deform during assembly in order to be attached.

[0092] As shown in FIG. 6C, the compression force is then removed from the force limiting spring 1054, causing the force limiting spring 1054 to expand toward a preloaded state between the anchor portion 1074 and the clip 1056, pushing the clip 1056 longitudinally within the window portion 1082 until the clip 1056 contacts the clip support surface 1081 of the body portion 1072 adjacent the proximal end of the window portion 1082 or the proximal ends of the first window 1084A and the second window 1084B.

[0093] The clip notches 1108A and 1108B may engage with the retaining ribs 1110A and 1110B (e.g., or another retaining element) as the clip 1056 moves proximally relative to the window notches 1112A and 1112B. FIG. 6C also illustrates the position of the clip 1056 relative to the drive body 1052 in a force limiting or overtravel state, where the drive body 1052 moves proximally relative to the clip 1056. Thus, the clip 1056 may move longitudinally within the first window 1084A and the second window 1084B in the window portion 1082. The clip 1056 may not move longitudinally outside the window portion 1082 because the body portion 1072 may stop the clip 1056 on either side of the window portion 1082.

[0094] The window notches 1112A and 1112B may function as slots to allow the clip 1056 to be assembled onto the retention ribs 1110A and 1110B. Maintaining the clip 1056 within the length of the retention ribs 1110A and 1110B is desirable because the engagement between the clip notches 1108A and 1108B and the retention ribs 1110A and 1110B retains the clip 1056 onto the drive body 1052 and the drive shaft 1026. Placing the clip 1056 on the window portion 1082 and within the first vertical slot 1070A and second vertical slot 1070B rotationally locks the clip 1056 to the drive body 1052 and rotationally and longitudinally locks the clip 1056 to the drive shaft 1026. The engagement between the retention ribs 1110A and 1110B and the clip notches 1108A and 1108B can aid in transferring rotational torque between the drive body 1052 and the clip 1056. Compressing the force-limiting spring 1054 and placing the clip 1056 on the drive body 1052 imparts a preload to the force-limiting spring 1054, which affects the amount of force required to initiate a force-limiting condition (e.g., an overtravel condition). The higher the preload on the force-limiting spring 1054, the more force a user must apply before the force-limiting condition is initiated.

[0095] FIG. 7A is an isometric view of a second example of a motion transfer assembly 1251, showing a cross section of the drive body 1252, clip 1256, and spring 1254 on the drive shaft 1226. FIG. 7B is an exploded view of the drive body 1252 and clip 1256, spring 1254, and drive shaft 1226. The drive body 1252 can include a body portion 1272, a window portion 1282, and an anchor portion 1274. FIGS. 7A and 7B are described together and include features for improving retention of the clip 1256 to prevent backout of the clip 1256 and for torque transfer from the drive body 1252 to the clip 1256. One advantage of the example of FIGS. 7A and 7B includes a doubling of slots and retention ribs to increase the surface area to facilitate torque transfer and prevent backout of the clip 1256.

[0096] The window portion may include a first window 1284A, a second window 1284B, a first retention rib 1210A, a second retention rib 1210B, a third retention rib 1210C, a fourth retention rib 1210D, a first window notch 1212A, a second window notch 1212B, a third window notch 1212C, and a fourth window notch 1212D.

[0097] The clip 1256 can include a clip body 1202, a proximal spring seat 1204, a clip slot 1206, a first clip notch 1208A, a second clip notch 1208B, a third clip notch 1208C, and a fourth clip notch 1208D. The drive shaft 1226 includes a first vertical slot 1270A and a second vertical slot 1270B.

[0098] The drive body 1252 has a clip 1256 that is disposed on the drive body 1252 and connected to the drive shaft 1226 that extends through the drive body 1252. The spring 1254 is disposed about the drive body 1252. The drive body 1252 generally has the same structure and function as the drive body 1252 described with respect to FIGS. 1A-6C, including a body portion 1272 and a window portion 1282 having a first window 1284A and a second window 1284B. However, the drive body 1252 has a third retaining rib 1210C, a fourth retaining rib 1210D, a third window notch 1212C, and a fourth window notch 1212D at the bottom of the drive body 1252, and the anchor portion 1274 may be cylindrical.

[0099] The first retention rib 1210A can extend from the top of the body portion 1272 into the first window 1284A. The first retention rib 1210A can extend from an upper portion of the top of the body portion 1272 such that the first retention rib 1210A forms a first lip on the top of the body portion 1272. The second retention rib 1210B can extend from the top of the body portion 1272 into the second window 1284B. The second retention rib 1210B can extend from an upper portion of the top of the body portion 1272 such that the second retention rib 1210B forms a second lip on the top of the body portion 1272. The first retention rib 1210A and the second retention rib 1210B can form a pair of retention ribs. The third retention rib 1210C may extend from a bottom of the body portion 1272 into the first window 1284A. The third retention rib 1210C may extend from a lower portion of the bottom of the body portion 1272 such that the third retention rib 1210C forms a third lip on the bottom of the body portion 1272. The fourth retention rib 1210D may extend from a bottom of the body portion 1272 into the second window 1284B. The fourth retention rib 1210D may extend from a lower portion of the bottom of the body portion 1272 such that the fourth retention rib 1210D forms a fourth lip on the bottom of the body portion 1272. The third retention rib 1210C and the fourth retention rib 1210D may form a pair of retention ribs. The first window notch 1212A may be part of the first window 1284A at the distal end of the first retention rib 1210A. The second window notch 1212B may be part of the second window 1284B at the distal end of the second retention rib 1210B. The third window notch 1212C may be part of the first window 1284A at the distal end of the third retention rib 1210C. The fourth window notch 1212D may be part of the second window 1284B at the distal end of the fourth retention rib 1210D.

[0100] The clip 1256 can have generally the same structure and function as the clip 1056 described with respect to FIGS. 1A-6C, including a clip body 1202, a proximal spring seat 1204, and a clip slot 1206. However, in some examples, the clip 1256 can further include a third clip notch 1208C and a fourth clip notch 1208D. The first clip notch 1208A can extend into the clip body 1202 from a first side of the clip slot 1206 at an upper portion of the clip slot 1206, and the second clip notch 1208B can extend into the clip body 1202 from a second side of the clip slot 1206 at an upper portion of the clip slot 1206. Thus, the second clip notch 1208B can extend into the clip body 1202 from the clip slot 1206 opposite the first clip notch 1208A. The third clip notch 1208C can extend into the clip body 1202 from a first side of the clip slot 1206 near the bottom of the clip slot 1206, and the fourth clip notch 1208D can extend into the clip body 1202 from a second side of the clip slot 1206 near the bottom of the clip slot 1206. Thus, the third clip notch 1208C is spaced apart from the first clip notch 1208A, and the fourth clip notch 1208D can extend into the clip body 1202 from the clip slot 1206 opposite the third clip notch 1208C and is spaced apart from the second clip notch 1208B. The drive shaft 1226 that receives the clip can be the same as or similar to the drive shaft 1226 described with respect to FIGS. 1A-6C and includes a first vertical slot 1270A and a second vertical slot 1270B.

[0101] When the drive body 1252 is on the drive shaft 1226, the clip 1256 can be disposed on the window portion 1282 of the drive body 1252. The clip slot 1206 can fit around the drive body 1252 at the window portion 1282 and can fit around the drive shaft 1226 at the first vertical slot 1270A and the second vertical slot 1270B such that the clip 1256 fits and is received within the first vertical slot 1270A and the second vertical slot 1270B of the drive shaft 1226. The proximal end of the spring 1254 can contact the proximal spring seat 1204 of the clip 1256. The first clip notch 1208A can fit around the first retention rib 1210A, which fits within the first clip notch 1208A. The second clip notch 1208B can fit around the second retention rib 1210B which fits within the second clip notch 1208B. The third clip notch 1208C can fit around the third retention rib 1210C which fits within the third clip notch 1208C. The fourth clip notch 1208D can fit around the fourth retention rib 1210D which fits within the fourth clip notch 1208D. The clip 1256 can move longitudinally within the first window 1284A and the second window 1284B of the window portion 1282 along the first retention rib 1210A, the second retention rib 1210B, the third retention rib 1210C, and the fourth retention rib 1210D.

[0102] Clip notches 1208A, 1208B, 1208C, and 1208D and retention ribs 1210A, 1210B, 1210C, and 1210D can be mated together to retain clip 1256 to drive body 1252 and drive shaft 1226, rotationally lock clip 1256 to drive body 1252, and simultaneously allow clip 1256 to move longitudinally along retention ribs 1210A, 1210B, 1210C, and 1210D within first window 1284A and second window 1284B. As a result, clip 1256 is prevented from jumping out of drive body 1252 and drive shaft 1226, while being allowed to move longitudinally along axis A1 (FIG. 1B) relative to drive body 1252.

[0103] The drive body 1252 has a third retaining rib 1210C and a fourth retaining rib 1210D that can fit into the third clip notch 1208C and the fourth clip notch 1208D of the clip 1256 so that the clip 1256 can be more evenly and securely retained on the drive body 1252 and the drive shaft 1226.

[0104] FIGURE 8A is an isometric view of a third example of a motion transmission assembly 1351, showing a cross section of a drive body 1352, a clip 1356, and a spring 1354 on a drive shaft 1326. FIGURE 8B is an exploded view of the drive body 1352, the clip 1356, the spring 1354, and the drive shaft 1326. The drive body 1352 can include a body portion 1372, a first retention rib 1310A, a second retention rib 1310B, a third retention rib 1310C, and a fourth retention rib 1310D. The clip 1356 can include a first clip notch 1308A, a second clip notch 1308B, a third clip notch 1308C, and a fourth clip notch 1308D. 8A and 8B are illustrated together and include features for improving retention of clip 1356 to prevent backout of clip 1356 and for torque transfer from drive body 1352 to clip 1356. One advantage of the example of FIGS. 8A and 8B includes doubling of slots and retention ribs to increase surface area to facilitate torque transfer and prevent backout of clip 1356.

[0105] The drive body 1352 may have a clip 1356 disposed thereon and coupled to the drive shaft 1326. The spring 1354 may be disposed around the drive body 1352. The drive body 1352 may have generally the same structure and function as the drive body 1252 described with respect to FIGS. 7A and 7B and includes a body portion 1372. However, the first retention rib 1310A, the second retention rib 1310B, the third retention rib 1310C, and the fourth retention rib 1310D may be thicker and longer. The first retention rib 1310A and the second retention rib 1310B may extend from all or most of the top of the body portion 1372. The third retention rib 1310C and the fourth retention rib 1310D may extend from all or most of the bottom of the body portion 1372.

[0106] Clip 1356 generally has the same structure and function as clip 1256 described with respect to Figures 7A and 7B. However, first clip notch 1308A, second clip notch 1308B, third clip notch 1308C, and fourth clip notch 1308D correspond to retention ribs 1310A, 1310B, 1310C, and 1310D which may be larger and deeper and may be thicker and longer. Drive shaft 1326 may be the same as drive shaft 1026 described with respect to Figures 1A-6C.

[0107] The clip notches 1308A, 1308B, 1308C, and 1308D and the retaining ribs 1310A, 1310B, 1310C, and 1310D can mate together to retain and rotationally lock the clip 1356 to the drive body 1352 and drive shaft 1326, while allowing the drive body 1352 to move longitudinally relative to the clip 1356 along the retaining ribs 1310A, 1310B, 1310C, and 1310D. As a result, the clip 1356 can be prevented or prevented from jumping out of the drive body 1352 and drive shaft 1326, while simultaneously allowing it to move longitudinally relative to the drive body 1352.

[0108] 9A is an isometric view of a fourth example of a motion transmission assembly 1451 and shows a cross section of the drive body 1452, clip 1456, and spring 1454 on the drive shaft 1426. FIG. 9B is an exploded view of the drive body 1452, clip 1456, spring 1454, and drive shaft 1426. The drive body 1452 can include a body portion 1472, a window portion 1482, and a strut 1418. The window portion 1482 can include a first window 1484A, a second window 1484B, a first retention rib 1410A, a second retention rib 1410B, a third retention rib 1410C, a fourth retention rib 1410D, a first window notch 1412A, a second window notch 1412B, a third window notch 1412C, and a fourth window notch 1412D. The struts 1418 can include a first strut 1418A and a second strut 1418B. The clip 1456 can include a clip body 1402, a clip slot 1406, a first clip notch 1408A, a second clip notch 1408B, a third clip notch 1408C, and a fourth clip notch 1408D. Figures 9A and 9B are described together to improve retention of the clip 1456 to prevent backout of the clip 1456 and include features for torque transfer from the drive body 1452 to the clip 1456. One advantage of the example of Figures 9A and 9B includes the doubling of the slots and retention ribs to increase the surface area to facilitate torque transfer and prevent backout of the clip 1456.

[0109] The drive body 1452 has a clip 1456 disposed thereon and connected to the drive shaft 1426, which may extend through the drive body 1452. A spring 1454 may be disposed about the drive body 1452.

[0110] 8A and 8B, includes a body portion 1472 and a window portion 1482 having a first window 1484A, a second window 1484B, retention ribs 1410A, 1410B, 1410C, and 1410D, and window notches 1412A, 1412B, 1412C, and 1412D. However, the window portion 1482 may include struts 1418. The top of the body portion 1472 at the window portion 1482 may be flat. If the top of the body portion 1472 at the window portion 1482 is flat, a tight connection between the profile of the retention ribs 1410A, 1410B, 1410C, 1410D and the profile of the respective window notches 1412A, 1412B, 1412C, and 1412D can be achieved. In this manner, the first retention rib 1410A, the top portion of the body portion 1472, and the second retention rib 1410B form the first strut 1418A. Similarly, the bottom of the body portion 1472 can be flat. In this manner, the third retention rib 1410C, the bottom portion of the body portion 1472, and the fourth retention rib 1410D can form the second strut 1418B. Thus, a first window 1484A may be between the first strut 1418A and the second strut 1418B on a first side of the body portion 1472, and a second window 1484B may be between the first strut 1418A and the second strut 1418B on a second side of the body portion 1472.

[0111] In some instances, it may be beneficial for the top of the body portion 1472 at the window portion 1482 to be flat, while in other embodiments, the top of the body portion 1472 at the window portion 1482 may not be flat or not substantially flat. Alternate shapes may be provided to provide a tight connection between the retention ribs 1410A, 1410B, 1410C, 1410D and the respective window notches 1412A, 1412B, 1412C, and 1412D.

[0112] 8A and 8B, includes a clip body 1402, a clip slot 1406, a first clip notch 1408A, a second clip notch 1408B, a third clip notch 1408C, and a fourth clip notch 1408D. However, the clip slot 1406, the first clip notch 1408A, and the second clip notch 1408B may have flat tops, while the third clip notch 1408C and the fourth clip notch 1408D may have flat bottoms to accommodate the struts 1418. The clip slot 1406 may extend to a lesser extent into the clip body 1402, and the top of the clip slot 1406 between the first clip notch 1408A and the second clip notch 1408B may be flat.

[0113] The drive shaft 1426 may be the same as the drive shaft 1026 described with respect to Figures 1A-6C. The clip notches 1408A, 1408B, 1408C, and 1408D and the retaining ribs 1410A, 1410B, 1410C, and 1410D may mate together to retain the clip 1456 to the drive body 1452 and drive shaft 1426 and rotationally lock the clip 1456 to the drive body 1452 while allowing the drive body 1452 to move longitudinally relative to the clip 1456 along the retaining ribs 1410A, 1410B, 1410C, and 1410D. As a result, the clip 1456 is prevented from jumping out of the drive body 1452 and drive shaft 1426 while at the same time allowing it to move longitudinally relative to the drive body 1452. Additionally, the clip slots 1406 may extend less into the clip body 1402 so that the clip body 1402 has more surface area to distribute the load from the springs 1454 .

[0114] 10A, 10B, 11A, and 11B show examples of how the drive shaft 1026 and outer shaft 1028 can be constrained to one another and to the outer hub 1060 and rotational actuator 1030. FIG. 10A shows a side view of a portion of the forceps of FIG. 1A, according to at least one example. FIG. 10A includes the outer shaft 1028, the outer hub 1060, the housing 1014, and the rotational actuator 1030 (shown in phantom). FIG. 10B shows a cross-sectional view of the rotational actuator 1030 and outer hub 1060 of FIG. 10A along line 10B-10B', but with the rotational actuator 1030 represented in solid lines, according to at least one example.

[0115] The outer hub 1060 may be disposed about at least a portion of the drive body 1052 and the drive shaft 1026. To transfer rotational motion from the outer hub 1060 to the drive shaft 1026, rotational motion received from the rotational actuator 1030 may be transferred to the outer hub 1060, from the outer hub 1060 to the drive body 1052, from the drive body 1052 to the clip 1056, and from the clip 1056 to the drive shaft 1026. Rotational input received from the rotational actuator 1030 may also be transferred from the outer hub 1060 to the outer shaft 1028 to rotate the outer shaft 1028. In another example, the clip 1056 may be omitted and / or a passageway 1092 (e.g., a bore) in the drive body 1052 may be rotationally keyed to the drive shaft 1026 to transfer the rotational input.

[0116] 10A and 10B in combination, at a proximal portion of the forceps 1000, a rotational actuator 1030 can be constrained to an outer hub 1060 via a keyed interface. For example, the rotational actuator 1030 can include an actuator hub keyed interface 1033 that is configured to be rotationally constrained to an outer hub 1060 having a complementary actuator hub keyed interface 1063. The keyed interfaces 1033, 1063 can constrain, couple, secure, lock, or limit rotation between the rotational actuator 1030 and the outer hub 1060.

[0117] In this arrangement, the outer hub 1060 may be configured to receive rotational input from the rotary actuator 1030 such that the rotary actuator 1030 and the outer hub 1060 may be rotated relative to the housing 1014. In alternative examples, the rotary actuator 1030 may be otherwise attached to the outer hub 1060, such as by molding, adhesive, welding, snap-fitting, or any other suitable method. In some examples, the rotary actuator 1030 may be omitted and the outer hub 1060 may function as an actuator and directly receive rotational input from a user. The rotary actuator 1030 is shown merely as one example of a component for receiving rotational input from a user, and any suitable rotational input device may be provided.

[0118] FIG 11A shows a side view of a portion of the forceps of FIG 1A, in accordance with at least one example, including the housing 1014, drive shaft 1026, outer shaft 1028, drive body 1052 (having a first portion 1052A and a second portion 1052B), force limiting spring 1054, drive link 1046, outer hub 1060 (shown in phantom), sleeve 1061, and jaw 1012. FIG 11B shows a cross-sectional view of the outer hub 1060 and drive body 1052 of FIG 11A along line 11B-11B', in accordance with at least one example, with the outer hub 1060 shown in solid lines.

[0119] To rotationally secure the outer hub 1060 to the drive body 1052, the outer hub 1060 and the drive body 1052 can include a hub-body keyed interface. For example, the outer hub 1060 can include an anti-rotation key 1100, and the drive body 1052 can have a complementary hub-body keyed interface, such as a rotational keying slot 1078. The rotational keying slot 1078 can be located in the second portion 1052B (e.g., a distal portion) of the drive body 1052. In this arrangement, the drive body 1052 can be configured to receive a rotational input from the outer hub 1060, which is provided to the outer hub 1060 by the rotational actuator 1030 (FIGS. 10A, 10B).

[0120] The anti-rotation key 1100 may include a ridge that extends from the inner surface 1098 of the outer hub 1060 into a channel formed by the inner surface 1098. The anti-rotation key 1100 may be sized to fit within a rotational keying slot 1078 of the outer hub 1060. The rotational keying slot 1078 may receive the anti-rotation key 1100 such that the rotational keying slot 1078 may be linearly translated or otherwise moved longitudinally along the anti-rotation key 1100 to allow retraction and extension of the drive body 1052 relative to the outer hub 1060 and housing 1014.

[0121] In other words, the anti-rotation key 1100 and rotational keying slot 1078 rotationally restrain the outer hub 1060 and drive body 1052, but the drive body 1052 can still move (e.g., slide, translate) relative to the outer hub 1060 along longitudinal axis A1 when the lever 1024 is actuated by a user ( FIG. 1B ). The longitudinal movement of the outer hub 1060 relative to the drive body 1052 allows the drive body 1052 to retract relative to the outer hub 1060 when the lever 1024 is actuated to close the jaws 1012. Such retraction of the drive body 1052 results in retraction of the drive shaft 1026 until a certain input force F1 is applied to the lever 1024 ( FIG. 13B ) that exceeds the preload of the force-limiting spring 1054. Once the input force F1 exceeds a certain input force, the drive body 1052 is allowed to continue to move proximally relative to the drive shaft 1026 without retracting the drive shaft 1026, thereby protecting the end effector 1002 from being damaged by excessive force.

[0122] Conventional forceps may include an outer shaft and an inner shaft that are only rotationally locked together at their distal ends near the end effector. In such a configuration, a rotational input received at a rotational actuator rotates only the proximal end of the outer shaft, but not the inner shaft, to rotate the jaws. In conventional forceps, only when the jaws rotate does the distal end of the inner shaft receive rotational motion from the connection of the outer shaft to the inner shaft proximal to the end effector, ultimately causing rotation of the inner shaft at its proximal end. A limitation of such a design is that the inner and outer shafts can "wind up" relative to each other, resulting in damage.

[0123] In contrast, the exemplary forceps 1000 may rotationally constrain the inner drive shaft 1026 to the outer shaft 1028 at a first longitudinal position and a second longitudinal position. In some examples, the first and second longitudinal positions may include first and second longitudinal regions. In the illustrative example of FIG. 11A, the drive shaft 1026 and the outer shaft 1028 may be rotationally constrained at both the proximal portion 1003 of the forceps 1000 and the distal portion 1005 of the forceps 1000. In this arrangement, the outer shaft 1028 and the drive shaft 1026 rotate together more uniformly, thereby being less likely to be damaged as the jaws 1012 rotate. An example of a connection at the proximal portion 1003 of the forceps 1000 is shown and described with continued reference to FIGS. 11A and 11B. Examples of connections at a distal portion 1005 of the forceps 1000 are shown and described with reference to Figures 20A-25.

[0124] To provide rotational constraint between the drive shaft 1026 and the outer shaft 1028 at the proximal portion of the forceps 1000, the drive shaft 1026 and the outer shaft 1028 may be rotationally constrained to one another via the drive body 1052 and the outer hub 1060.

[0125] The outer hub 1060 may be fixedly coupled to the outer shaft 1028 to transfer rotational motion from the outer hub 1060 to the outer shaft 1028. In one example, a sleeve 1061 may be attached to the outer hub 1060 and also attached to the outer shaft 1028. The sleeve 1061 may be attached to an inner surface 1098 of the outer hub 1060, although the sleeve 1061 may be attached to another portion of the outer hub 1060. In some examples, the sleeve 1061 may be omitted and the outer hub 1060 may be directly or otherwise attached to the outer shaft 1028.

[0126] The outer hub 1060 can be longitudinally constrained relative to the housing 1014 while remaining rotatable relative to the housing 1014. This can be accomplished, for example, by the outer hub 1060 including a proximal housing flange 1060A and a distal flange 1060B, which longitudinally constrain a portion of the housing 1014 therebetween.

[0127] In an illustrative example, the interface between the proximal housing flange 1060A and the housing 1014 may restrain the outer hub 1060 from moving in a distal direction relative to the housing 1014. In a corresponding manner, the interface between the distal housing flange 1060B and the housing 1014 may restrain the outer hub 1060 from moving in a proximal direction relative to the housing 1014. One advantage of this arrangement is that it prevents the outer hub 1060 from moving longitudinally relative to the housing 1014, but does not affect the ability of the outer hub 1060 to rotate relative to the housing 1014, thereby rotating the end effector 1002. In another example, the housing 1014 may additionally or alternatively include a flange to interface with the outer hub 1060, thereby providing a similar longitudinal restraint. In some examples, a single flange may include one or more interfaces with the housing 1014 to longitudinally restrain the outer hub 1060 relative to the housing. In some examples, instead of a proximal housing flange 1060A and a distal housing flange 1060B, a single flange can provide an interface that longitudinally constrains the outer hub 1060 to the housing 1014. For example, a single flange on the outer hub 1060 or a single flange on the housing 1014 interfaces such that the single flange is bounded proximally and distally by the other of the outer hub 1060 and the housing 1014. Such alternative geometries are within the scope of this disclosure.

[0128] To transfer rotational motion from the outer hub 1060 to the drive shaft 1026, transfer may occur from the outer hub 1060 through the clip 1056 to the drive body 1052 and drive shaft 1026. To transfer rotational motion from the outer hub 1060 to the outer shaft 1028, the outer hub 1060 may be fixedly coupled to the outer shaft 1028. An example of attachment of the outer hub to the outer shaft is shown and described in Figures 9 and 10.

[0129] By rotationally constraining the drive shaft 1026 and outer shaft 1028 to the outer hub 1060 at a proximal end and the drive shaft 1026 to the outer shaft 1028 at a distal end proximate the end effector (e.g., jaws 1012), the forceps 1000 may be made less susceptible to twisting of the drive shaft 1026 relative to the outer shaft 1028 along the intermediate portion 1006 (FIG. 1B) between the hand piece 1001 and the end effector 1002. Reducing twisting of the drive shaft 1026 and outer shaft 1028 reduces "wind-up" of the drive shaft 1026 relative to the outer shaft 1028. Limiting "wind-up" may improve a user's ability to control the end effector 1002, thereby limiting undesired movement (e.g., unwinding, spring-back) of the end effector 1002. Examples illustrating constraining rotation at the distal end of the forceps (eg, distal to the outer hub 1060, proximal to the end effector 1002) are further described herein with respect to Figures 20A-25.

[0130] In some examples, the first longitudinal location (e.g., 1003) can be closer to the hand piece 1001 than the end effector 1002 and the second longitudinal location (e.g., 1005) can be closer to the end effector 1002 than the hand piece 1001. The second longitudinal location (e.g., 1005) can be distal to the first longitudinal location (e.g., 1003). The second longitudinal location (e.g., 1005) can be proximal to the end effector 1002. The second longitudinal location (e.g., 1005) can be proximal to the end effector 1002 that couples to the drive shaft 1026 or the outer shaft 1028.

[0131] The outer shaft 1028 can extend from a proximal end proximate the hand piece 1001 to a distal end proximate the end effector 1002. In some examples, the second longitudinal position (e.g., 1005) can be located in a range between 75% and 95% of the distance D1 from the proximal end to the distal end of the outer shaft 1028.

[0132] 12 is a partial cross-sectional view of a portion of an exemplary forceps 1700 showing another example of a hub-body interface. FIG. 12 shows a drive body 1752 with an anchor portion 1774 including another example of an anti-rotation key 1706, and a hub 1760 including a rotational keying slot 1710. The drive body 1752, outer shaft 1728, and drive shaft 1726 are not shown in cross section. The forceps 1700 can include a drive body 1752 (including an anchor portion 1774 with an anti-rotation key 1706), a hub 1760 (including a rotational keying slot 1710 and an inner surface 1712), a rotation knob 1730 (e.g., a rotation actuator), an outer shaft 1728, and a drive shaft 1726.

[0133] 1A-6C and 10A-11B, except that the drive body 1752 may include an anchor portion 1774 (e.g., a distal portion) having an anti-rotation key 1706, and the hub 1760 has a rotational keying slot 1710. The anti-rotation key 1706 may be a protrusion or ridge extending from a side of the anchor portion 1774. The anti-rotation key 1706 may be sized to fit within the rotational keying slot 1710 of the hub 1760. The hub 1760 may have the rotational keying slot 1710 extending from an inner surface 1712 into the hub 1760.

[0134] The rotational keying slot 1710 can receive an anti-rotation key 1706, which is disposed within the rotational keying slot 1710. The anti-rotation key 1706 can be of a length that is shorter than the length of the rotational keying slot 1710, such that the anti-rotation key 1706 and drive body 1752 can be linearly translated along the rotational keying slot 1710 and hub 1760. In other words, the anti-rotation key 1706 and rotational keying slot 1710 prevent relative rotation between the hub 1760 and the drive body 1752, while the anti-rotation key 1706 can function, at least in part, as a guide for longitudinal movement of the drive body 1752 relative to the hub 1760.

[0135] The anti-rotation key 1706 and rotational keying slots 1710 may connect and rotationally lock the hub 1760 and the drive body 1752. Thus, rotating the rotation knob 1730 rotates the hub 1760, which rotates the drive body 1752. As a result, rotating the rotation knob 1730 causes both the outer shaft 1728 and the drive shaft 1726 to rotate together.

[0136] In some examples, any of the anti-rotation interfaces described herein may replace the geometry of the keyed interface, or the keyed interface may include a different interface geometry.

[0137] FIG. 13A illustrates a side view of a portion of the forceps 1000 of FIG. 1A with the lever 1024 in an unactuated position (e.g., the drive shaft 1026 is not retracted and the jaws 1012 are open), according to at least one example. FIG. 13B illustrates a side view of a portion of the forceps 1000 of FIG. 1A with the lever 1024 in an actuated position (e.g., the drive shaft is retracted and the jaws are closed), according to at least one example. FIG. 13C illustrates a side view of a portion of the forceps 1000 of FIG. 1A with the lever 1024 in a force-limiting state (e.g., the jaws are stuck open and in an overtravel position), according to at least one example. FIGs. 13A, 13B, and 13C all illustrate the lever 1024 in various actuated positions, with the trigger 1034 in an unactuated position. Figures 13A, 13B, and 13C show close-up views of a portion of the handpiece 1001 shown and described with respect to Figures 4A, 4B, and 4C. The outer hub 1060, lever 1024, and trigger 1034 are shown in phantom, allowing some hidden parts within the handpiece 1001 to be seen.

[0138] FIG. 13A shows the lever 1024 and trigger 1034 in their unactuated positions. As shown in FIG. 13B, moving the lever 1024 in a proximal direction (by force F1) actuates a linkage, in this example a four-bar type mechanism, which can indirectly retract the drive shaft 1026. The four links can include a first link L1 (e.g., a ground link), a second link L2, a third link L3, and a fourth link L4. The first link L1 can be the housing 1014 that provides a ground for the linkage. The second link L2 can be provided by a portion of the lever 1024. The third link L3 can be a coupling link 1042 connected between the second link L2 and the fourth link L4, and the fourth link L4 can be a drive link 1046. It is noted that the ground link L1 is supplied by the housing 1014, but the ground link L1 could also be the frame or a separate link fixed to the housing 1014 or the frame.

[0139] A second link L2 (e.g., lever 1024) may be pivotally coupled to a ground link L1 (e.g., first link, housing 1014, frame). A first movable element, such as a drive body 1052, may be operatively coupled to the second link L2 (e.g., lever 1024) by a linkage including a third link L3 (e.g., coupling link 1042) and a fourth link L4 (e.g., drive link 1046). Actuating the second link L2 (e.g., lever 1024, movable handle or another actuator) provides an input to the linkage (L1, L2, L3, L4) to move the drive body 1052 relative to the ground link L1 (e.g., housing 1014).

[0140] In other words, moving the lever 1024 proximally can cause the drive link 1046 of the four-bar mechanism to pivot about the drive link pivot axis A2, or another articulation mechanism, to provide an input to the drive body 1052 and retract the drive shaft 1026. In the example of the forceps 1000, this action closes the jaws 1012, as shown in FIG. 13B. In some examples, retraction of the drive shaft 1026 can cause a different effect in addition to closing the jaws 1012 when used with a different end effector. In some examples, there can be fewer or more than four links in the mechanism, such as a five-bar, six-bar, or greater than six-bar mechanism. Applying the linkage (L1, L2, L3, L4) to the non-limiting example of FIGS. 13A, 13B, and 13C, the lever 1024 is pivotally coupled to the housing 1014 and the drive link 1046 is pivotally coupled to the housing 1014.

[0141] As further described and labeled in FIG. 13B, moving the actuable end of the lever 1024 in a proximal direction causes the lever 1024 to rotate relative to the housing 1014 about the first pin 1038, which causes a first portion 1042B of the coupling link 1042 to move proximally. This movement also causes a second portion 1042C of the coupling link 1042 to move proximally. This causes the drive link 1046 to pivot relative to the housing 1014, such that the portion of the drive link 1046 that is coupled to the coupling link 1042 at the third pin 1048 and that engages the drive body 1052 at the distal face 1088B (FIG. 13B) moves proximally. As a result, when the lever 1024 is reversed and allowed to move distally, all of these actions are reversed by the lever return spring 1040, and in some cases, the drive link 1046 may be engaged with the drive body 1052 at the proximal face 1089A (FIG. 13B).

[0142] In situations where the lever 1024 is pulled proximally and the jaws 1012 encounter some resistance, the drive shaft is placed under a tensile load. This can occur if there is an obstruction between the jaws 1012, such as when tissue or another medical device is placed between the jaws 1012, or if the jaws 1012 are fully closed and the lever 1024 continues to actuate. In this tensile state, there is a tensile load on the drive link 1046 and may also be a tensile load on the coupling link 1042. The advantage of such a tensile state is that relatively thin components can be used in the mechanism, which are more stable under tension than under compression, which allows the lever 1024 to operate more smoothly than devices that rely on creating a compression state in the components.

[0143] As shown in the inset of Figure 13A, the coupling link 1042 can have a body 1042A that extends from a first portion 1042B pivotally coupled to the lever 1024 to a second portion 1042C pivotally coupled to the drive link 1046. The coupling link 1042 can include a tab 1043 (or multiple tabs) that extends away from the body 1042A. The coupling link 1042 can reside within a lever recess 1025 of the lever 1024 (see cross-sectional view of the lever 1024 in Figure 3B).

[0144] The tab 1043 can have one or more functions, including functioning as a shut-off tab to prevent the trigger 1034 from being prematurely or inadvertently actuated until the lever 1024 is at least partially actuated. The tab 1043 can include one or more shut-off tab portions. The tab 1043 can extend away from a central portion of the body 1042A located between the first and second portions. The tab 1043 can include a first shut-off tab portion 1043A that extends away from the body 1042A in a direction toward the trigger 1034 at an acute angle α relative to the axis A4 of the body. The first shut-off tab portion 1043A can include a shelf extending in a proximal-distal direction to receive the trigger 1034.

[0145] The trigger 1034 may be operably coupled to the housing 1014, such as by a pivotable coupling 1041. The trigger 1034 may function as a second lever or a second actuator for actuating a function of the end effector 1002. The trigger 1034 may be operably coupled to a second movable element, such as, but not limited to, a spool 1064 (e.g., a second motion transmission or cutting block). When actuated, the trigger 1034 may move the spool 1064 relative to the housing 1014. The trigger 1034 may include a blocking surface 1035 having one or more blocking surface portions, examples of which are labeled in FIG. 13B.

[0146] 13A, a tab 1043 on the coupling link 1042 may be positioned to engage at least a portion of a blocking surface 1035 of the trigger 1034 and limit movement of the trigger 1034 until the lever 1024 is at least partially actuated. In the example where the trigger 1034 extends the blade shaft 1032 to actuate the cutting action of the blade 1032A (FIG. 2), this prevents actuation of the blade 1032A until the jaws 1012 are at least partially closed or snapped shut.

[0147] 13B, when lever 1024 is at least partially actuated, tab 1043 may move such that a clearance is created between tab 1043 and blocking surface 1035, allowing trigger 1034 to be at least partially actuated. Blocking surface 1035 may include multiple blocking surfaces, for example, first blocking surface portion 1035A and second blocking surface portion 1035B.

[0148] In an illustrative example, starting in the non-actuated position of FIG. 13A, as shown in the combination of FIG. 13A and FIG. 13B, the first blocking tab portion 1043A may engage with the first blocking surface portion 1035A and / or the second blocking tab portion 1043B may engage with the second blocking surface portion 1035B.

[0149] In the transition between the blocking position of FIG. 13A (e.g., engaged position, unactuated lever 1024) and the non-blocking position of FIG. 13B (e.g., disengaged position, actuated position of lever 1024), different portions of tab 1043 may engage and support different portions of blocking surface 1035 throughout the kinematics of linkages L1, L2, L3, L4. This is because as the orientation of coupling link 1042 changes relative to lever 1024 and drive link 1046, the orientation of tab 1043 relative to trigger 1034 may also change. The kinematics may affect which portion(s) of tab 1043 engages and supports which portion(s) of blocking surface 1035.

[0150] For example, when the lever 1024 is pulled and the tab 1043 transitions from the blocking position of Figure 13A to the non-blocking position of Figure 13B, the first blocking tab portion 1043A may be in less engagement with the first blocking surface portion 1035A, while the second blocking tab portion 1043B may play a greater role in preventing or limiting actuation of the trigger 1034. In some examples, prior to disengagement, the second blocking tab portion 1043B may move and engage the first blocking surface portion 1035A or the third blocking surface portion 1035C, and then be fully released from the trigger 1034, allowing the trigger 1034 to be actuated or at least partially actuated.

[0151] 13B and 13C show two different non-blocking positions, with Fig. 13B showing the lever 1024 in an actuated position and Fig. 13C showing the lever 1024 in a second actuated position where the force F1 being applied to the lever 1024 is great enough to activate the force limiting aspect of the motion transmission assembly 1051. As shown in Fig. 13B, as the lever 1024 moves through its range of motion due to the force F1 applied by the user, the tab 1043 moves out of the way of the trigger 1034 such that the tab 1043 no longer engages the blocking surface 1035 and the trigger 1034 can be actuated. In the non-blocking position, the first blocking tab portion 1043A may not engage with the first blocking surface portion 1035A, the second blocking surface portion 1035B, or the third blocking surface portion 1035C, and the second blocking tab portion 1043B may not engage with any of the first blocking surface portion 1035A, the second blocking surface portion 1035B, or the third blocking surface portion 1035C.

[0152] The illustrative forceps 1000 presents only one example of actuation system components coupled to the housing 1014. In various examples, the components may be disposed within or outside the housing 1014. For example, at least a portion of the second link L2 (e.g., lever 1024) may be disposed within or outside the housing 1014. At least a portion of the fourth link L4 (e.g., drive link 1046) may be disposed within or outside the housing 1014. At least a portion of the trigger 1034 may be disposed within or outside the housing 1014. At least a portion of the third link L3 (e.g., coupling link 1042) may be disposed within or outside the housing 1014. In some examples, at least a portion of the third link L3 (e.g., coupling link 1042) may be external to the housing 1014 for the full range of motion of the third link L3.

[0153] FIGURE 14A illustrates a side view, a proximal isometric view, and a distal isometric view of an exemplary drive link 1046 of the forceps of FIGURE 1A, according to at least one example. FIGURE 14B illustrates a proximal isometric view, and a distal isometric view of the drive link 1046 of the forceps of FIGURE 1A, according to at least one example.

[0154] 14A, 14B, and 14C show example surfaces of the drive link 1046 and will be described together. As described above with respect to FIGS. 4A, 4B, 4C, 13A, 13B, and 13C, the drive link 1046 is operably coupled to the housing 1014. The drive link 1046 can be configured to transfer an input force F1 received from an actuator, such as the lever 1024, to linear motion of the drive body 1052 and drive shaft 1026. The drive link 1046 can transfer the force to the drive body 1052 via one or more cam surfaces of the drive link 1046. 14A, 14B, and 14C in combination, drive link 1046 can include one or more proximal cam surface(s) 1045A, 1045B formed on a proximal side of drive link 1046 and one or more distal cam surface(s) 1047A, 1047B formed on a distal side of drive link 1046. Proximal cam surfaces 1045A and 1045B can be disposed on opposite sides of distal cam surfaces 1047A, 1047B in a longitudinal direction of forceps 1000 such that proximal cam surface 1045A faces away from distal cam surface 1047A and proximal cam surface 1045B faces away from distal cam surface 1047B. To drive the drive body 1052 (FIG. 5A) in a proximal direction (e.g., to retract the drive shaft 1026 and close the jaws 1012), the proximal cam surfaces 1045A, 1045B can be configured to interface with a collar 1088 shown in FIG. 5A. To drive the drive body 1052 (FIG. 5A) in a distal direction (e.g., to extend the drive shaft 1026 and open the jaws 1012), the distal cam surfaces 1047A, 1047B can be configured to interface with a distal surface or collar 1089 shown in FIG. 5A.

[0155] To improve the user's ergonomic experience with the handpiece 1001, maximize space efficiency, and minimize the overall length of the forceps 1000, especially in the longitudinal direction (L1, FIG. 1B), the cam surfaces 1045A, 1045B, 1047A, and 1047B may be formed as portions of concentric cylinders. For example, in FIG. 14A, the portions of the concentric cylinder 1049 are shown as portions of cylinders of equal diameter (e.g., as D1), but this is not required. The proximal cam surfaces 1045A, 1045B may be of a different diameter than the distal cam surfaces 1047A, 1047B, but still remain concentric with one another about a common axis A3. For example, at least one of the proximal cam surfaces 1045A, 1045B can be formed as at least a portion of a first cylindrical surface 1049A having a diameter D1, while at least one of the distal cam surfaces 1047A, 1047B can be formed as at least a portion of a second cylindrical surface 1049B having a diameter D2, such that at least a portion of the first cylindrical surface 1049A and at least a portion of the second cylindrical surface 1049B are concentric about a common axis A3.

[0156] In some examples, during the range of motion of the drive link 1046, the common axis A3 of the proximal camming surfaces 1045A, 1045B and the distal camming surfaces 1047A, 1047B is configured to pass below the drive link pivot axis A2. In some examples, the common axis A3 is configured to pass through a surface perpendicular to the translation axis A4 of the drive body 1052, a plane passing through the drive link pivot axis A2. In some examples, during the range of motion of the drive link 1046, the common axis A3 is configured to pass through the translation axis A4 of the drive body 1052 twice. The translation axis A4 can be an axis that is coincident with or parallel to the longitudinal axis A1 shown in FIG. 1B.

[0157] In some examples, the proximal and distal cam surfaces 1045A, 1045B, 1047A, 1047B may be formed by portions of cylindrical surfaces (e.g., 1049A and / or 1049B) such that the surfaces of the drive body 1052 that drive the cam surfaces 1045A, 1045B, 1047A, 1047B are positioned to tangent to the associated cam surfaces throughout the range of motion. For example, as shown in the combination of Figures 5A and 14A, the proximal cam surfaces 1045A, 1045B include a circular shape such that the distal surface 1088B of the proximal collar 1088 may contact the proximal cam surfaces 1045A, 1045B at a location that tangent to the proximal cam surfaces 1045A, 1045B throughout the range of motion of the drive link 1046. The range of motion of the drive link 1046 may correspond to the displacement of the jaws 1012 from an open position to a closed position (the position of the jaws 1012 shown in FIGS. 1A and 1B). One advantage of this arrangement is that the distance from the proximal cam surface 1045A to the distal cam surface 1047A remains the same throughout the rotation of the drive link 1046. Because of this constant distance between the proximal cam surface 1045A and the distal cam surface 1047A (and similarly between the cam surfaces 1045B and 1047B), the distance between the distal surface 1088B of the proximal collar 1088 and the proximal surface 1089A of the distal collar 1089 may be shortened to a set distance. This is more space efficient and provides a smoother movement compared to conventional forceps.

[0158] Although the cam surfaces 1045A, 1045B, 1047A, 1047B are shown and described with reference to a yoke and a drive link 1046 having two proximal cam surfaces 1045A, 1045B and two distal cam surfaces 1047A, 1047B, any number of cam surfaces may be provided. In some examples, the drive link 1046 need not be yoke shaped and may include more than one cam surface. For example, the drive link may have only one leg and include a single proximal cam surface 1045A and a single distal cam surface 1047A. In another example, the drive link may have a non-uniform number of cam surfaces, for example, a single proximal cam surface 1045A and two distal cam surfaces 1047A, 1047B, or vice versa. In some examples, there may be any combination of two or more cam surfaces (e.g., 1045A, 1045B, 1047A, 1047B) such that at least two opposing cam surfaces each include a portion of a cylindrical surface, and the portions of the cylindrical surface are concentric about a common axis A3.

[0159] In some examples, the drive link 1046 may include one or more cam surfaces. In such examples, the drive body 1052 may include a surface (e.g., distal surface 1088B of collar 1088, FIG. 5A ) for receiving a drive surface (e.g., cam surface 1045A) of the drive link 1046. In such examples, the drive surface may include a portion of a cylinder having an axis (e.g., A3) configured to pass under the drive link pivot axis A2 as the drive link 1046 passes through its range of motion and / or pass through the longitudinal axis of translation A1 of the drive body 1052 as the drive link 1046 passes through its range of travel. One advantage of such kinematics is that the distance the proximal collar 1088 or distal collar 1089 must be driven for a minimum amount of lever force F1 is optimized.

[0160] The common axis A3 can be perpendicular to a plane passing through the longitudinal axis A1 (FIG. 1B) along which the drive body 1052 translates and intersects the drive link 1046. The common axis A2 can be parallel to the drive link pivot axis A2 of the drive link 1046 to the housing 1014.

[0161] FIG 15A illustrates a cross-sectional view of a portion of the forceps 1000 of FIG 1A with the lever 1024 in an actuated position and the trigger 1034 in an unactuated position, according to at least one example. FIG 15A is similar to FIG 13C and illustrates a position in which the clamping function has been actuated by the lever 1024 such that the jaws 1012 are closed by the action of the first motion transmission assembly 1051 causing retraction of the drive body 1052 and the drive shaft 1026, but the blades 1032A are not yet actuated.

[0162] 1A with lever 1024 in an actuated position and trigger 1034 in an actuated position (e.g., blade 1032A is extended), according to at least one example. In some examples, trigger 1034 need not specifically be a trigger, but may be a second lever or another type of second actuator.

[0163] As shown in FIG. 15A, the trigger return spring 1068 biases the trigger 1034 to a first position (e.g., default position, unactuated position, retracted position) so that the blade shaft 1032 remains in a retracted state until the trigger 1034 is compressed and moved proximally to actuate the blade 1032A (FIG. 2). In the first unactuated position, the spool 1064 is in a proximal position on the drive shaft 1026. The cross pin 1066 is in a proximal position within the first horizontal slot 1069A and the second horizontal slot 1069B. Thus, the trigger return spring 1068 is in a relaxed state floating between the drive body 1052 and the spool 1064, or between the second distal spring seat 1091 and the proximal trigger return spring seat 1101. The blade shaft 1032 is in a proximal position and the blade shaft 1032 is retracted.

[0164] To facilitate extension and retraction of the blade shaft 1032 and blade 1032A (FIG. 2), the cross pin 1066 may travel within one or more opening(s) (e.g., elongated openings) in the drive shaft 1026, such as a first horizontal slot 1069A and a second horizontal slot 1069B (hidden). The first and second horizontal slots 1069A and 1069B may act as guide rails for the longitudinal reciprocating motion of the spool 1064. Thus, the spool 1064 may be guided along and by the drive shaft 1026. The first horizontal slot 1069A may extend to a first side of the drive shaft 1026 and the second horizontal slot 1069B may extend to a second side of the drive shaft 1026 across from or opposite the first horizontal slot 1069A. The first horizontal slot 1069A and the second horizontal slot 1069B may be near a proximal portion or end of the drive shaft 1026 and may extend along a longitudinal axis A1 (FIG. 1B) of the drive shaft 1026. Thus, the cross pin 1066 may extend from the first arm 1034C of the trigger 1034 to the second arm 1034D (hidden) of the trigger 1034 through the spool 1064, the first horizontal slot 1069A of the drive shaft 1026, the blade shaft 1032, and the second horizontal slot 1069B of the drive shaft 1026. The spool 1064 may include a proximal trigger return spring seat 1101 at a distal end of the spool 1064. Thus, the trigger return spring 1068 can be disposed on the drive shaft 1026 between the proximal end of the drive body 1052, or the second distal spring seat 1091, and the distal end of the spool 1064, or the proximal trigger return spring seat 1101.

[0165] 15B, to extend the blade 1032A, a user can apply an actuation force input F2 to the trigger 1034. The trigger 1034 can be configured to receive the force input F2 from the user and transmit the force input to the spool 1064 via at least one arm 1034C of the trigger 1034. When the trigger 1034 is compressed to the second actuation position (and a distal portion of the trigger 1034 is moved proximally), the trigger 1034 moves the spool 1064 distally relative to the housing 1014 and the cross pin 1066 moves distally within the first horizontal slot 1069A and the second horizontal slot 1069B. The spool 1064, e.g., a proximal trigger return spring seat 1101 of the spool 1064, may press the trigger return spring 1068 against a second distal spring seat 1091, allowing the spool 1064 to continue to move distally, until the preload of the trigger return spring 1068 is overcome and the trigger return spring 1068 is compressed. The cross pin 1066 may be constrained to the blade shaft 1032, e.g., by extending through a bore 1032B (FIG. 2) of the blade shaft 1032, thereby constraining the cross pin 1066 to the blade shaft 1032. As a result, the blade shaft 1032 may be moved distally to an extended position such that the blade 1032A (FIG. 2) may be visible at the distal end of the forceps 1000, or may be extended distally between the closed jaws 1012, but not necessarily visible. When the trigger 1034 is disengaged from the second position, the trigger return spring 1068 may expand and push against the proximal trigger return spring seat 1101, driving the spool 1064 proximally relative to the housing 1014. In this manner, the cross pin 1066 may move proximally within the first horizontal slot 1069A and the second horizontal slot 1069B, moving the blade shaft 1032 proximally to a retracted position such that the blade 1032A (FIG. 2) is no longer visible at the distal end of the forceps 1000. When no force is applied to the trigger 1034, the trigger 1034 returns to the first position (FIG. 15A).

[0166] The proximal portion 1034A of the trigger 1034 may include one or more arms 1034C, 1034D (better seen in FIG. 17D). In this example, the first arm 1034C is laterally spaced from the second arm 1034D to form a yoke that receives the spool 1064, which in turn may be connected to the drive shaft 1026 by a cross pin 1066 extending therethrough. Thus, because of the cylindrical shape of the spool 1064, and because the spool 1064 is not fixedly coupled to the arms 1034C, 1034D, the spool 1064 may rotate relative to the arms 1034C, 1034D of the trigger 1034, causing the drive shaft 1026 to rotate. In other words, the spool 1064 is rotatable with the drive shaft 1026 and is not inhibited by the arms 1034C, 1034D of the trigger 1034. This trigger 1034 to spool 1064 interface may be described as a yoke-to-spool cam connection (similar to the connection between the drive link 1046 and the drive body 1052). The yoke-to-spool cam connection allows the internal drive shaft 1026 and blade shaft 1032 to rotate while simultaneously engaging the trigger 1034 with the spool 1064 to impart movement of the spool 1064 along the longitudinal axis A1 (FIG. 1B).

[0167] The spool 1064 comprises a beneficial shape that allows the trigger 1034 to extend the blade shaft 1032 while the drive shaft 1026 extends through the spool 1064 and rotates under the input of the rotary actuator 1030. As shown in the combination of the retracted position of the blade 1032A in FIG. 15A and the extended position of the blade 1032A in FIG. 15B, the body, such as but not limited to the exemplary spool 1064, can be configured to be guided by the drive shaft 1026 to displace the blade shaft 1032, and thus the blade 1032A, between the retracted and extended positions.

[0168] The spool 1064 need not be provided as an axisymmetric spool or as having a cylindrical body to permit rotation of the spool 1064 relative to the trigger 1034. Alternatively, the spool 1064 may include a non-cylindrical body, such as a rectangular prism or an irregular shape in examples that do not include a rotatable drive shaft, such as when the drive shaft is rotatably fixed relative to the housing and can translate relative to the housing. In some examples, the spool 1064 may be described as a body, a second body, a second motion transmission body, a cutting body, or a second drive body.

[0169] 15A and 15B, the drive shaft 1026 can extend from a location proximal to the drive body 1052, through the spool 1064, and toward the proximal end of the housing 1014. An advantage of the drive shaft 1026 extending through a second passageway 1064A (FIG. 2) in the spool 1064 and proximally past the spool 1064 to the proximal end of the housing 1014 where it is supported by the stabilizing flange 1021 is that the drive shaft 1026, in addition to providing an actuation function to the jaws 1012, can also function as a guide or rail for the spool 1064 to ride along. In some examples, the drive shaft 1026 may extend through the stabilizing flange 1021.

[0170] When the spool 1064 is disposed on or around the drive shaft 1026, the spool can move longitudinally along the drive shaft 1026, and while an axisymmetric spool 1064 is shown, other examples of second motion transmission bodies can include those that are not specifically spools. In some such examples, such second motion transmission bodies can be guided by the drive shaft 1026, but the second motion transmission body does not necessarily have to surround the drive shaft 1026 and need not be spool-shaped or rotatable. The spool 1064 is shown as one example of a motion transmission body, designed to transmit motion received from an actuator to a shaft (e.g., received from the trigger 1034 and transmitted to the blade shaft 1032). In other examples, the motion transmission bodies of the present disclosure need not be spool-shaped, such as in examples where the spool 1064 does not need to be rotatable.

[0171] The trigger return spring 1068 may be a helical compression spring disposed on the drive shaft 1026 between the distal end of the spool 1064 and the proximal end of the drive body 1052. Conventional trigger return springs have the disadvantage that they are generally backed up against a fixed flange of the housing. The exemplary trigger return spring 1068 is a floating spring disposed between the spool 1064 and the drive body 1052, and has the advantage that there is no need to design a flange in the housing 1014 that must interface with the trigger return spring 1068. The axial stacking along the direction of the forceps' longitudinal axis A1 (FIG. 1B) can be reduced, shortening the length of the forceps 1000 and improving ergonomics. In addition, the trigger return spring 1068 may be easily assembled by loading it onto the drive shaft 1026, and thus, in contrast to conventional forceps, there is no additional assembly step of fixing the spring end to a flange in the housing.

[0172] Figure 16A is a cross-sectional view of a portion of forceps 1000 along line 16A-16A' of Figure 15A with trigger 1034 in the unactuated position of Figure 15A, in accordance with at least one example. Figure 16B is a cross-sectional view of a portion of forceps 1000 along line 16B-16B' of Figure 15A with trigger 1034 in the actuated position of Figure 15B, in accordance with at least one example. Figures 16A and 16B will be described together.

[0173] 16A, the spool 1064 can extend from a proximal end portion to a distal end portion and can include one or more peripheral flanges (e.g., 1067A, 1067B) extending outwardly from minor diameter D3 toward the housing 1014. In this example, the spool 1064 includes a proximal flange 1067A, a distal flange 1067B, and a minor diameter D3 extending therebetween along the longitudinal axis A1.

[0174] When the distal portion 1034B of the trigger 1034 is moved proximally, the arms 1034C, 1034D of the trigger 1034 slide along the minor diameter D3 of the spool 1064 until the arms 1034C, 1034D contact the distal flange 1067B of the spool 1064. When the arms 1034C, 1034D contact the distal flange 1067B, the arms 1034C, 1034D can press against the distal flange 1067B of the spool 1064. As the distal portion 1034B of the trigger 1034 continues to be actuated in the proximal direction, the arms 1034C, 1034D press against the distal flange 1067B, causing the spool 1064 to slide distally along the drive shaft 1026 relative to the housing 1014, thereby extending the blade assembly, including the blade shaft 1032, relative to the housing 1014.

[0175] When the user finishes actuating the blade 1032A and releases the actuation force input F2 on the trigger 1034, the distal portion of the trigger 1034 may be moved distally by the unloading force of the compressed trigger return spring 1068. As the arms 1034C, 1034D of the trigger 1034 slide along the minor diameter D3 of the spool 1064, the arms 1034C, 1034D may eventually contact the proximal flange 1067A of the spool 1064. When the arms 1034C, 1034D contact the proximal flange 1067A, the arms 1034C, 1034D press against the proximal flange 1067A of the spool 1064 under the force of the compressed trigger return spring 1068, causing the spool 1064 to slide proximally along the drive shaft 1026 back to the default proximal position of FIG. 15A, thereby retracting the blade shaft 1032 relative to the housing 1014.

[0176] 16A and 16B, one or both of the proximal flange 1067A and the distal flange 1067B may be tapered flanges, for example, double tapered flanges. This allows for better angles between the components of the handpiece 1001, improving kinematics and ease of use. However, if excessive force is applied by the user to move the trigger 1034 proximally, the arms 1034C, 1034D of the trigger 1034 will splay, deflect, or bend laterally outward from the longitudinal axis A1, disengaging the arms 1034C, 1034D of the trigger 1034 from the spool 1064. In other words, the magnitude of the actuation input force F2 (FIG. 16B) is such that at least one of the arms 1034C, 1034D is deformed laterally outward in the direction L or L'.

[0177] To manage the spreading of one or more of the arms 1034C, 1034D, the housing 1014 may include one or more control surfaces 1013C, 1015D configured to prevent spreading of one or more of the arms. Spreading most likely occurs when the arms 1034C, 1034D apply a force to the distal flange 1067B at the distal end of the travel of the arms 1034C, 1034D. Spreading may also occur, but is less likely, when the arms 1034C, 1034D apply a force to the proximal flange 1067A at the proximal end of the travel of the arms 1034C, 1034D. For example, a first control surface 1013C may extend toward the first arm 1034C, such that the lateral spread of the first arm 1034C is controlled by the first control surface 1013C. Similarly, the second control surface 1015D may extend toward the second arm 1034D, with the lateral extent of the second arm 1034D being controlled by the second control surface 1015D.

[0178] In some examples, the control surface 1013C, 1015D may be coupled to or integrally formed with the first housing portion 1016 or the second housing portion 1018. As shown in the example of FIG. 16A and FIG. 16B, one or more control surfaces 1013C, 1015D may be provided as rib(s) 1017C, 1017D formed on the inside of the first housing portion 1016 and the second housing portion 1018 extending inwardly toward the arms 1034C, 1034D. The first rib 1017C may be disposed opposite or opposite the second rib 1017D. The first rib 1017C may extend inwardly along a proximal-distal direction from a first inner surface 1016A of the first housing portion 1016. The second rib 1017D may extend inwardly along a proximal-distal direction from the second inner surface 1018A of the second housing portion 1018. With the arms 1034C, 1034D forming a yoke disposed around the spool 1064, the arms 1034C, 1034D may be restrained between the first rib 1017C and the second rib 1017D. In this arrangement, when one of the arms 1034C, 1034D tries to push one of the ribs 1017C, 1017D to spread outward, the arm 1034C or 1034D is restrained by the rib 1017C or 1017D and maintained inward, such that the arm 1034C or 1034D maintains contact with the spool 1064 to transmit force from the yoke of the trigger 1034 to the spool 1064. In some examples, the trigger 1034 may include only one arm and the housing may include only one rib or other control surface.

[0179] In another example, the control surfaces 1013C, 1015D that prevent (e.g., restrain, limit, constrain) the spread of the arms 1034C, 1034D may not be provided as ribs 1017C, 1017D, but rather may include shaped inner surfaces 1016A, 1018A of the housing 1014 that are arranged in a manner or positioned relative to at least one of the arms 1034C, 1034D to constrain the lateral spread of the arms 1034C, 1034D, thereby preventing the arms 1034C, 1034D from disengaging from the proximal or distal flanges 1067A, 1067B of the spool 1064. In some examples, the respective arms 1034C, 1034D and control surfaces 1013C, 1015D may contact one another along at least a portion of the full range of motion of the arms 1034C, 1034D. For example, the movement of arms 1034C, 1034D between the unactuated position of FIG. 16A and the actuated position of FIG. 16B.

[0180] To manage the lateral expansion of the arms 1034C, 1034D, a gap 1019C, 1019D, or no gap may be provided between the first arm 1034C and the first control surface 1013C, and between the second arm 1034D and the second control surface 1015D. For example, as shown in FIG. 16A, the gap 1019C may be disposed between the first control surface 1013C and the first arm 1034C along at least a portion of the first control surface 1013C. The first gap 1019C may have a distance less than the arm thickness 1034E of the first arm 1034C to prevent the first arm 1034C from expanding outward when the trigger 1034 is actuated to the extent that the first arm 1034C disengages from the distal flange 1067B. In some examples, the second gap 1019D can have a distance that is less than the second arm thickness 1034F of the second arm 1034D.

[0181] In some examples, the arm thickness 1034E or 1034F may be in the range of about 0.5 mm to 4 mm, and the distance of the respective gap 1019C or 1019D may be in the range of about 10 to 90% of the arm thickness 1034E or 1034F. In another example, the arm thickness 1034E or 1034F may be in the range of about 0.5 to 3.0 mm, and the respective gap 1019C or 1019D may be in the range of about 10 to 60% of the arm thickness 1034E or 1034F. In a perhaps more preferred example, the arm thickness 1034E or 1034F may be in the range of about 1 to 2 mm, and the distance of the respective gap 1019C or 1019D may be in the range of about 10 to 50% of the arm thickness 1034E or 1034F. In a perhaps even more preferred example, the arm thickness 1034E or 1034F may be in the range of 1.4 mm to 1.7 mm, and the distance of the gap 1019C or 1019D may be in the range of 0.1 mm to 0.75 mm.

[0182] The placement of the arm thickness 1034E or 1034F compared to the distance of the respective gap 1019C or 1019D may also be defined by the ratio of the distance of the gap 1019C or 1019D compared to the distance of the respective arm thickness 1034E or 1034F (e.g., the gap arm ratio). For example, the gap arm ratio may be between 1 / 10 and 9 / 10 (e.g., the gap is 10-90% of the arm thickness). However, depending on the device specifications, in possibly more preferred examples the gap arm ratio may be about 30%±25%, or the gap arm ratio may range between about 1 / 5 and 3 / 5 (e.g., the gap distance is 20%-60% of the arm thickness). In some possibly preferred examples, the ratio may be less than 1 / 2, or range between 10%-50%, to prevent the arms 1034C and 1034D from spreading.

[0183] When the trigger 1034 is actuated, the first arm 1034C and the first rib 1017C can contact each other along at least a portion of the range of motion of the first arm 1034C. Similarly, the second arm 1034D and the second rib 1017D can contact each other along at least a portion of the range of motion of the second arm 1034D.

[0184] FIG. 17A is a side view of a subassembly 1500 of the forceps 1000 of FIG. 1A. The subassembly 1500 is held by hand during assembly, according to at least one example, with some components shown in phantom. FIG. 17B is a side view of the subassembly 1500 of FIG. 17A inserted into a housing (e.g., second housing portion 1018), according to at least one example, with some components shown in phantom. FIG. 17C is a side view of the subassembly 1500 and second housing portion 1018 of FIG. 17B, according to at least one example, shown in solid lines. FIG. 17D is a proximal isometric view of the subassembly 1500 and second housing portion 1018 of FIG. 17C, according to at least one example. FIGs. 17A, 17B, 17C, and 17D are described together.

[0185] When assembling a medical device such as the forceps 1000, it can be difficult to assemble a set of links to multiple pivot attachments in the housing. Parts tend to move around, making it difficult to align the multiple pivots with corresponding attachments in the housing. To improve ease of assembly, the inventors have discovered that a nested subassembly 1500 can be inserted in alignment with the housing 1014.

[0186] 17A may be formed and held as a temporary subassembly 1500 by the hand of an assembler. For example, the subassembly 1500 may be held together with the nested arrangement of the lever 1024, coupling link 1042, and trigger 1034 by the support of a user's hand. Assembly is improved because creating the subassembly 1500 allows both the lever pivot 1027 on the lever 1024 and the trigger pivot 1037 on the trigger 1034 to be aligned and coupled in one step (e.g., simultaneously in one motion) with the pivot attachments on the second housing portion 1018.

[0187] 17A-17D in combination, the boss 1027A can extend around at least a portion of the lever pivot 1027. The lever pivot 1027 can interface with the housing 1014 to allow the lever 1024 to rotate about the lever pivot axis P1 (FIG. 17C).

[0188] The trigger 1034 may include an arm 1034C having a recess 1039 configured to receive the boss 1027A. A coupling link 1042 pivotally coupled to the lever 1024 may include a body 1042A and a tab 1043 extending away from the body 1042A. As shown and described in FIGS. 13A, 13B, 13C, the tab 1043 on the coupling link 1042 may be positioned to provide support to an inner surface of the trigger 1034 (e.g., blocking surface 1035 shown and described in FIGS. 13A, 13B, 13C) when the boss 1027A is seated in the recess 1039. The tab 1043 may extend at an acute angle from the body 1042A toward the inner surface of the trigger 1034 (e.g., 1035). In the illustrated example, the tab 1043 may extend away from a central portion of the body 1042A. In another example, the tab 1043 can extend away from any portion of the body 1042A, including the ends of the body 1042A.

[0189] 18 illustrates a method 1800 of assembling a medical device, for example, forceps 1000, including the subassembly 1500 of FIGS. 17A-17D. In act 1802, the method 1800 can include pivotally connecting a coupling link 1042 to a first lever, such as lever 1024. The coupling link 1042 can include a body 1042A and a tab 1043 extending away from the body 1042A, and the lever 1024 can include a lever pivot 1027 and a boss 1027A.

[0190] Operation 1804 may include nesting the lever 1024 and coupling link 1042 with a second lever, e.g., a trigger 1034 having a trigger pivot 1037. In the nested position, a recess 1039 of the trigger 1034 may be supported by a boss 1027A. In some examples, the nesting step of operation 1804 may include inserting the coupling link 1042 and lever 1024 between two spaced apart arms 1034C, 1034D of the trigger 1034. Operation 1806 may include supporting an inner surface (e.g., 1035) of the trigger 1034 with the coupling link 1042 to provide a subassembly 1500 held in a subassembled state.

[0191] With the subassembly 1500 held in the assembler's hand, operation 1808 may include pivotally coupling the lever pivot 1027 to the housing 1014 (e.g., or frame) and pivotally coupling the trigger pivot 1037 to the housing 1014. The coupling of the lever pivot 1027 and the trigger pivot 1037 in operation 1808 may be performed, for example, simultaneously, substantially simultaneously, or in a single operation or step. Pivotally coupling the lever 1024 to the housing 1014 may include aligning the lever pivot 1027 and boss 1027A with a lever pivot attachment 1017A on the housing 1014. Pivotally coupling the trigger 1034 to the housing 1014 may include aligning the trigger pivot 1037 with a trigger pivot attachment 1017B on the housing 1014.

[0192] In some examples, the recess 1039 is supported by the boss 1027A and an inner surface (e.g., 1035) of the trigger 1034 is supported by a tab 1043 such that the lever pivot 1027 can be connected to the lever pivot attachment 1017A of the housing 1014 and the trigger pivot 1037 can be connected to the trigger pivot attachment 1017B of the housing 1014 without disengaging the recess 1039 from the boss 1027A.

[0193] In a sub-assembled state, the lever pivot 1027 and the trigger pivot 1037 can have a similar distance D2 relative to the distance between the lever pivot attachment 1017A and the trigger pivot attachment 1017B on the housing 1014. A similar distance can include, but is not limited to, the same distance, the same distance within reasonable manufacturing and assembly tolerances, a distance that facilitates assembly of the lever 1024 and the trigger 1034 to the housing 1014 in one step. In some examples, the distance D2 can be measured between the lever pivot axis P1 and the trigger pivot axis P2 when assembled.

[0194] Although method 1800 is described with reference to forceps 1000 of FIG. 1A, method 1800 may be performed to assemble a frame, a first lever having a first pivot, a second lever having a second pivot (e.g., without limitation, a trigger), a coupling link, and another medical device having first and second pivot attachments onto the frame.

[0195] Fig. 19A illustrates a distal end of the forceps 1000 of Fig. 1A, including, in accordance with at least one example, routing of a wire harness 1900. Fig. 19B illustrates a portion of the forceps 1000 of Fig. 1A, including, in accordance with at least one example, routing of the wire harness 1900 of Fig. 19A.

[0196] The wire harness 1900 can supply electromagnetic energy to, for example, activate one or more electrodes of the end effector 1002 of FIG. 1A. The wire harness 1900 can enter the housing 1014, for example, at the handle portions 1020A, 1020B. The wire harness 1900 can include one or more low voltage wires and one or more high voltage wires. For example, as shown in FIG. 21, the wire harness 1900 can include a pair of low voltage wires 1902 and a pair of high voltage wires 1904 grouped together within a polymer cover 1906.

[0197] As the multiple high and low voltage wires move within the housing 1014, the wires may be separated into a pair of low voltage wires 1902 and a pair of high voltage wires 1904. The pair of low voltage wires 1902 may be routed to one or more switches 1914 via a connector 1912, which may form part of a flexible printed circuit board. The one or more switches 1914 may be, for example, dome switches that are actuable by an actuation button 1036. The pair of high voltage wires 1904 may be routed to one or more electrical couplings 1908A, 1908B that are in electrical communication with the end effector 1002. In one example, the low voltage pair of wires 1902 may carry a 12 volt DC current to an actuation button 1036 (FIG. 1A). The actuation button 1036 may include or be coupled to one or more switches, such as, for example, two dome switches with the actuation button 1036 floating above a flexible circuit board with the switches. When the activation button 1036 is pressed, a post or hook of the activation button 1036 can depress the dome switch 1914, closing a circuit.

[0198] The activation button 1036 may be a wrap-around multi-directional button. The activation button 1036 may be pressed anywhere and in any direction on the button to activate the switch 1914. Features on the activation button 1036, such as a post or hook formed on the inner surface facing the switch 1914, along with two laterally spaced dome switches 1914 on either side of the handpiece 1001, allow the activation button 1036 to be activated from many directions. This arrangement allows for easy activation by the user. In this example, the two switches 1914 are positioned approximately symmetrically about the longitudinal axis of the forceps 1000.

[0199] The low voltage pair of wires 1902 may include a ground wire and a reference wire that form a closed circuit. In one example, the high voltage pair of wires 1904 may carry a 2265 volt, 450,000 Hz, 505 amp current with waveforms that are out of phase with each other. The high voltage pair of wires 1904 may carry power to the end effector 1002.

[0200] The pair of high voltage wires 1904 may terminate in an electrical coupling 1908 where they may be electrically coupled to a pair of wires 1910 (hereinafter, "drive shaft wires") that travel through the drive shaft 1026. The electrical coupling 1908 and the drive shaft wires 1910 facilitate adapting the single wire harness 1900 to accommodate forceps having drive shafts 1026 of different lengths. The pair of drive shaft wires 1910 may enter the proximal end of the drive shaft 1026, travel through the drive shaft 1026 along the blade shaft 1032, and exit the distal end of the drive shaft 1026. The pair of drive shaft wires 1910 may be coupled to the end effector 1002 at the distal end of the drive shaft 1026. In some examples, the pair of high voltage wires 1904 may power one or more electrodes of the jaws 1012. The routing of the drive shaft wires 1910 proximate the end effector 1002 is described further herein.

[0201] FIG 20A shows an isometric view of a portion of forceps 2000 in a closed position, in accordance with at least one example of the present disclosure. FIG 20B shows an isometric view of a portion of forceps 2000 in a partially open position. FIG 20C shows an isometric view of a portion of forceps 2000 in an open position. FIG 20A-C also show axis A1 and proximal and distal directional indicators. FIG 20A-C are discussed simultaneously below.

[0202] The forceps 2000 may be a surgical forceps consistent with the description above such that the forceps 2000 may be manipulated to open and close jaws to grasp tissue, apply electrical energy to tissue, and / or cut tissue for use during a surgical, biopsy, or therapeutic procedure. Any of the features of the forceps 2000, or any of the forceps or end effectors described below, may be included in the forceps described above. Further details of the forceps 2000 are discussed below.

[0203] The forceps 2000 may include an upper jaw 2010, a lower jaw 2012, a guide (or proximal pin) 2014, a drive pin 2016, and a pivot pin 2018. The upper jaw 2010 may include flanges 2020a and 2020b (collectively referred to as flanges 2020) and an upper gripping plate 2023, and the lower jaw 2012 may include flanges 2022a and 2022b (collectively referred to as flanges 2022) and a lower gripping plate 2024 (the flanges 2020 and 2022 may also be referred to as struts herein). The forceps 2000 may also include an inner shaft 2026 (or inner tube or drive shaft), an outer shaft 2028 (or outer tube), and a distal plug 2030. The inner shaft 2026 may include inner arms 2034a and 2034b (collectively referred to as inner arms 2034). The outer shaft 2028 may include outer arms 2038a and 2038b (collectively referred to as outer arms 2038). The flanges 2020a and 2020b may include tracks 2040a and 2040b, respectively (collectively referred to as tracks 2040). The flanges 2022a and 2022b may include tracks 2042a and 2042b, respectively (collectively referred to as tracks 2042). The portion of the forceps 2000 shown in FIGS. 20A-C may be referred to as an end effector 2002.

[0204] Each of the components of the forceps 2000 may be made of a material such as one or more of metal, plastic, foam, elastomer, ceramic, composite material, combinations thereof, etc. The materials of some of the components of the forceps are discussed in further detail below.

[0205] The jaws 2010 and 2012 can be rigid members configured to engage tissue. The jaws 2010 and 2012 can be coupled to an outer shaft 2028 and pivotally coupled, for example, via a pivot pin 2018. The pivot pin 2018 can extend through a portion of the jaws 2010 and 2012 (such as a bore in each of the jaws 2010 and 2012) such that the pivot pin 2018 can be received by an outer arm 2038 of the outer shaft 2028. In another example, the jaws 2010 and 2012 can be pivotally coupled to the outer shaft 2028 via a boss (or bosses) of the outer shaft 2028. In another example, the jaws 2010 and 2012 can include a boss (or bosses) receivable within a bore of the outer shaft 2028 to pivotally couple the jaws 2010 and 2012 to the outer shaft 2028. In another example, the outer shaft 2028 may include a boss (or bosses) receivable within bores in the jaws 2010 and 2012 to pivotally couple the jaws 2010 and 2012 to the outer shaft 2028.

[0206] Flanges 2020a and 2020b (which may be a set of flanges, i.e., two flanges) may be rigid or semi-rigid members disposed on a proximal portion of jaw 2010. Similarly, flanges 2022a and 2022b may be rigid or semi-rigid members disposed on a proximal portion of jaw 2012. In some examples, flange 2020 may be disposed laterally outboard of inner flange 2022. In another example, flanges 2020 and 2022 may be interlaced.

[0207] Grip plates 2023 and 2024 of jaws 2010 and 2012, respectively, may be rigid or semi-rigid members configured to engage tissue and / or the opposing jaw to grasp tissue, such as during electrosurgery. One or more of the grip plates 2023 and 2024 may include one or more of serrations, protrusions, ridges, etc. configured to increase engagement pressure and friction between the grip plates 2023 and 2024 and tissue. The flange 2020 of the upper jaw 2010 may extend proximally away from the grip plates 2023 and 2034, and in some instances may extend substantially downwardly when the upper jaw 2010 is in an open and partially open position (as shown in FIGS. 20B and 20C, respectively). Similarly, the flange 2022 of the lower jaw 2012 can extend proximally away from the grip plate and in some instances can extend substantially upwardly when the upper jaw 2010 is in an open and partially open position (as shown in FIGS. 20B and 20C, respectively), such that the jaws 2010 and 2012 and the flanges 2020 and 2022 move to open and close in a scissor manner. The jaws 2010 and 2012 can each include an electrode configured to deliver electricity to tissue (optionally via the grip plates 2023 and 2024), a frame supporting the electrode, and a blade slot configured to receive a blade between the jaws 2010 and 2012, as described in more detail below.

[0208] The track 2040 of the flange 2020 and the track 2042 of the flange 2022 may be tracks, channels, paths, or slots in the flanges 2020 and 2022, respectively. In some examples, the tracks 2040 and 2042 may be disposed proximally of the pivot pin 2018 when the pivot pin 2018 is coupled to the jaws 2010 and 2012 (and optionally the outer shaft 2028). The tracks 2040 and 2042 may be shaped to receive the drive pin 2016 therein. In some examples, the tracks 2040 and 2042 may be slots or channels configured to receive the drive pin 2016 therethrough, connecting the drive shaft 2026 (such as the inner arm 2034a and / or the inner arm 2034b) to the flanges 2020 and 2022 (and thus the jaws 2010 and 2012).

[0209] The tracks 2040 and 2042 can be straight in some examples and can be arc shaped in some examples. In any example, the tracks 2040 and 2042 can be configured to allow the drive pin 2016 to move simultaneously along the tracks 2040 and 2042 to open and close the jaws.

[0210] Each of the inner shaft 2026 and the outer shaft 2028 can be a rigid or semi-rigid elongated body having a cylindrical geometry, where the shape of the inner shaft 2026 matches the shape of the outer shaft 2028. In some examples, the inner shaft 2026 and the outer shaft 2028 can have another shape, such as an elliptical prism, a rectangular prism, a hexagonal prism, an octagonal prism, etc. In some examples, the inner shaft 2026 and the outer shaft 2028 can be shaped such that the inner shaft 2026 cannot rotate relative to the outer shaft 2028, but the inner shaft 2026 can still translate relative to the outer shaft. For example, the inner shaft 2026 and the outer shaft 2028 can be concentric elliptical prisms. In another example, the inner shaft 2026 and the outer shaft 2028 can be rectangular tubes sized to limit the relative rotation of the inner shaft 2026 to the outer shaft 2028. In some examples, the shape of the inner shaft 2026 can be different from the shape of the outer shaft 2028.

[0211] The inner shaft 2026 may extend substantially from the proximal to the distal direction along an axis A1, which may be a longitudinal axis. Similarly, the outer shaft 2028 may extend substantially from the proximal to the distal direction along the axis A1. In some examples, the axis A1 may be a central axis of one or more of the inner shafts 2026 and the outer shaft 2028. The inner shaft 2026 may include an axial bore extending along the axis A1. The outer shaft 2028 may also include an axial bore extending along the axis A1. The inner shaft 2026 may have an outer dimension (e.g., an outer diameter) that is smaller than an inner diameter of the outer shaft 2028, such that the inner shaft 2026 is disposed within the outer shaft 2028 and is translatable therein along the axis A1. The inner shaft 2026 may be referred to as a drive shaft 2026, a camshaft 2026, or an inner tube 2026. The outer shaft 2028 may also be referred to as an outer tube 2028.

[0212] The inner arms 2034a and 2034b (distal arms) of the inner shaft 2026 can extend distally from a distal portion of the inner shaft 2026, and the inner arms 2034a and 2034b can be disposed laterally outward of the flanges 2020 and 2022. In some examples, the inner arms 2034a and 2034b together can form a fork or clevis. The outer arms 2038a and 2038b can extend distally from a distal portion of the outer shaft 2028 to form a fork or clevis. In some examples, the outer arms 2038a and 2038b can extend distally beyond the inner arms 2034a and 2034b to receive a pivot pin 2018 therein and secure the flanges 2020 and 2022 (and thus the jaws 2010 and 2012) to the outer shaft 2028.

[0213] Jaw 2010 can include flanges 2020a and 2020b, and jaw 2012 can include flanges 2022a and 2022b. Jaws 2010 and 2012 can each include two flanges to help distribute the force applied to the jaws by drive pin 2016. For example, using two flanges per jaw can help reduce the force applied to tracks 2040 and 2042 by drive pin 2016 during opening and closing of jaws 2010 and 2012. Using two flanges per jaw can also help stabilize the operation of the jaws since pin 2016 has multiple contact points with each jaw. That is, drive pin 2016 contacts flanges 2020a and 2020b and flanges 2022a and 2022b, respectively.

[0214] The distal plug 2030 may be a plug positionable within the outer shaft 2028 between the outer arms 2038, and the inner arms 2034 may translate about the distal plug. The distal plug 2030 may include a blade channel extending therethrough, allowing the blades 2032 to extend through (and translate relative to) the distal plug 2030. The distal plug 2030 may include one or more conduit bores therethrough to receive conduits (connected to the electrodes of the jaws 2010 and 2012). The distal plug 2030 is described in more detail below.

[0215] The blade 2032 may be an elongated cutting member including one or more sharp edges configured to cut or ablate tissue or another item. The blade 2032 may be disposed within the outer shaft 2028 (and the inner shaft 2026) and may extend along (and optionally parallel to) axis A1. The blade 2032 may be translatable relative to the inner shaft 2026 and the outer shaft 2028 and may extend between (or within) the first jaw 2010 and the second jaw 2012. In some examples, the blade 2032 may extend axially through the inner shaft 2026 and may be laterally offset from axis A1. In some examples, the blade 2032 may extend axially through the flanges 2020 and 2022 such that the blade 2032 is in a position laterally inward of the first set of flanges 2020 and the second set of flanges 2022.

[0216] Each of the guide 2014, drive pin 2016, and pivot pin 2018 may be a rigid or semi-rigid pin, such as a cylindrical pin. The guide 2014, drive pin 2016, and pivot pin 2018 may be another shape in other examples, such as rectangular, square, oval, etc. In some examples, each pin is the same size (e.g., diameter and length), which can simplify manufacturing and reduce costs. Each pin may have a smooth surface, which can help reduce surface friction between the pin and a component of the forceps 2000, such as between the pivot pin 2018 and the outer shaft 2028, or between the drive pin 2016 and the flanges 2020 and 2022. In some examples, each of the guide 2014, drive pin 2016, and pivot pin 2018 may be another component, such as one or more protrusions, bosses, arms, etc.

[0217] The operation of the forceps 2000 is explained below in the description of FIG. 21 with reference to FIGS. 20A-20C.

[0218] FIG 21 illustrates a side view of a portion of forceps 2000 in an open position, in accordance with at least one example of the present disclosure. FIG 21 also illustrates axis A1 and proximal and distal portions of a directional indicator. The forceps 2000 of FIG 21 may correspond to the forceps described with respect to FIG 20A-C, and FIG 21 illustrates the forceps 2000 with a phantom outer shaft 2028.

[0219] FIG. 21 also shows outer slots 2044a and 2044b (only slot 2044b is visible in FIG. 21). Outer slots 2044a and 2044b (collectively referred to as outer slots 2044) can be axial slots that extend through opposing portions of the outer shaft 2028. In some examples, outer slot 2044a can be on an opposite arm 2038a of the outer tube 2028 from outer slot 2044b on arm 2038b. Outer slot 2044 can be sized to receive drive pin 2016 therein such that drive pin 2016 can translate along outer slot 2044 (as inner shaft 2026 translates relative to outer shaft 2028) in examples where drive pin 2016 extends laterally outward from an outer surface of inner shaft 2026. In some examples, the outer slot 2044 may be a track that extends partially through the outer shaft 2028 (and does not pass completely through the outer shaft 2028).

[0220] In some example operations, a handle (such as those discussed above) may be manipulated to translate the inner shaft 2026 within (and relative to) the outer shaft 2028. For example, distal translation of the inner shaft 2026 relative to the outer shaft 2028 translates the drive pin 2016 distally, moving the jaws 2010 and 2012 from a closed position (as shown in FIG. 20A ) to an intermediate position (as shown in FIG. 20B ) to an open position (as shown in FIG. 20C and 431 ). Conversely, proximal translation of the inner shaft 2026 may translate the drive pin 2016 proximally, moving the jaws 2010 and 2012 to a closed position, such that the drive pin 2016 may translate to open and close the jaws 2010 and 2012 in a scissor manner. In another example, the action can be reversed, with distal movement of the inner shaft 2026 moving the jaws 2010 and 2012 toward a closed position, and proximal movement of the inner shaft 2026 moving the jaws 2010 and 2012 toward an open position.

[0221] In particular, in one example, distal translation of the inner shaft 2026 may cause the drive pin 2016 to translate distally within the outer slot 2044, which helps to guide the axial translation of the drive pin 2016 by helping to limit rotation of the inner shaft 2026 relative to the outer shaft 2028, and by helping to limit non-axial movement of the inner shaft 2026 relative to the outer shaft 2028. As the drive pin 2016 translates distally in the outer slot 2044, the drive pin 2016 may translate distally along (such as within) the track 2040 of the flange 2020 of the upper jaw 2010, and along the track 2042 of the flange 2022 of the lower jaw 2012. Because the tracks 2040 and 2042 may be angled and / or curved along the flanges 2020 and 2022, respectively, and because the tracks 2040 and 2042 may be oriented in opposite directions relative to one another, distal translation of the drive pin 2016 may cause the jaws 2010 and 2012 to open in a scissor-type motion, i.e., the upper jaw 2010 moves upward, its flange 2020 moves downward, and the lower jaw 2012 moves downward and its flange 2022 moves upward, moving the upper jaw 2010 and lower jaw 2012 toward (and ultimately to) an open position.

[0222] Distal translation of the inner shaft 2026 may be limited by contact between the drive pin 2016 and a distal end of each outer slot 2044 (as shown in FIG. 21 ). In some examples, distal translation of the inner shaft 2026 may be limited by contact between the drive pin 2016 and a distal end of each of the tracks 2040 and 2042. In another example, distal translation of the inner shaft 2026 may be limited by contact between the guide 2014 and a portion of the inner shaft 2026.

[0223] To close the jaws, the inner shaft 2026 can be translated proximally to translate the drive pin 2016, which translates the drive pin 2016 proximally within the outer slot 2044. As the drive pin 2016 translates proximally in the outer slot 2044, the drive pin 2016 may translate proximally along (such as within) the track 2040 of the flange 2020 of the upper jaw 2010 and along the track 2042 of the flange 2022 of the lower jaw 2012. The proximal translation of the drive pin 2016 may cause the jaws 2010 and 2012 to close in a scissor-type motion. That is, the upper jaw 2010 moves downward, its flange 2020 moves upward, the lower jaw 2012 moves upward and its flange 2022 moves downward, and the upper jaw 2010 and lower jaw 2012 move toward (and ultimately to) the closed position.

[0224] The proximal translation of the inner shaft 2026 may be limited by contact between the drive pin 2016 and the proximal end of each outer slot 2044. In some examples, the proximal translation of the inner shaft 2026 may be limited by contact between the drive pin 2016 and the proximal end of each of the tracks 2040 and 2042. In another example, the proximal translation of the inner shaft 2026 may be limited by contact between the guide 2014 and a portion of the inner shaft 2026. In another example, the proximal translation of the inner shaft 2026 may be limited by contact between the jaws 2010 and 2012 (or by limiting the pivotal movement of the clamp lever relative to the housing, as shown in FIG. 4C ).

[0225] When the jaws 2010 are in a partially closed position (as shown in FIG. 20B) or when the jaws are not in a fully open position, the blade 2032 may extend partially into the jaws 2010 and 2012 to cut tissue between the jaws 2010 and 2012. The blade 2032 may be extended by manipulating a trigger on a handle (or another actuator), as described above. When the jaws 2010 are in a closed position (as shown in FIG. 20A), the blade 2032 may be fully extended into the jaws 2010 and 2012 to cut tissue between the jaws 2010 and 2012. Using these manipulations, a physician may use the forceps 2000 to grasp tissue with the jaws 2010 and 2012 and to cut tissue using the blade 2032 to remove tissue from a patient. More details about the forceps are provided below.

[0226] 22 illustrates a top view of a portion of the forceps 2000 in an open position with the outer shaft 2028 removed, in accordance with at least one example of the present disclosure. FIG 22 illustrates the proximal and distal directional indicators and the axis A1.

[0227] The forceps 2000 of Figure 22 can be consistent with the forceps 2000 described above, with further details being described with respect to Figure 22. For example, Figure 22 shows that the arms 2034a and 2034b of the inner shaft 2026 can include bores 2046a and 2046b, respectively, which can be sized and shaped to receive the drive pin 2016 therein (and in some instances through).

[0228] FIG. 22 also shows that the flange 2020 can be positioned laterally outboard of the flange 2022. FIG. 22 also shows that the flange 2020 can be positioned laterally inboard of the arm 2034 such that a gap exists between the flanges 2022a and 2022b such that the arm 2034 can control the outward lateral position of the flange 2020 (and thus the flange 2022). The blade 2032 can be positioned between the flanges 2022 such that the blade 2032 can translate parallel to the axis A1 without contacting the flanges 2022 or 2020. The blade 2032 positioned between the flanges 2022 can also allow the blade 2032 to be positioned at or near the center of the inner shaft 2026 and the jaws 2010 and 2012, which can help the blade 2032 extend along or near a central portion of the jaws 2010 and 2012 to improve the cutting operation using the blade 2032. In some examples, the flange 2022 also allows the blade 2032 to be laterally inboard of the flange 2022 while still being offset from the axis A1.

[0229] FIG. 22 also illustrates that the pivot pin 2018 and the drive pin 2016 can extend through the blade 2032. FIG. 22 further illustrates that the drive pin 2016 can extend through the flanges 2020 and 2022 and the arm 2034. FIG. 22 further illustrates that the guide 2014 can define a length PL1, the drive pin 2016 can define a length PL2, and the pivot pin 2018 can define a length PL3. In some instances, the lengths PL1, PL2, and PL3 can all be the same to help simplify the bill of materials and construction of the forceps 2000. However, the lengths PL1, PL2, and PL3 can be different in other instances.

[0230] 23 shows an isometric view of the inner shaft 2026 of the forceps 2000, in accordance with at least one example of the present disclosure. FIG. 23 also shows proximal, distal, upper, and lower directional indicators.

[0231] The inner shaft 2026 can be consistent with the description of the inner shaft 2026 above, with Figure 23 showing additional details of the inner shaft 2026, such as flats 2048a and 2048b (only 2048a is visible in Figure 23) on arms 2034a and 2034b, respectively. The flats 2048 can be of a size and shape that allows the flanges 2020 and 2022 to be positioned within the arms 2034, and can be substantially parallel surfaces configured to reduce contact and friction between the flanges 2020 and 2022 and the arms 2034 during opening and closing of the jaws 2010 and 2012.

[0232] 23 also shows axial tracks 2050a and 2050b (collectively referred to as axial tracks 2050). The axial tracks 2050 may also be referred to as axial slots or channels or proximal slots of the inner shaft 2026. The axial tracks 2050 may each be an axial slot that extends laterally through a wall of the inner shaft 2026. In another example, the axial tracks 2050 may be a channel, groove, recess, or other guide configured to receive a guide member. In some examples, the axial tracks 2050 do not extend entirely through the inner shaft 2026.

[0233] Axial track 2050a (not fully visible in FIG. 23) can include a distal edge 2052a, a proximal edge 2054a, a lower edge 2056a, and an upper edge 2058a. Axial track 2050b can include a distal edge 2052b, a proximal edge 2054b, a lower edge 2056b, and an upper edge 2058b. One or more of the axial tracks 2050 can be sized and shaped to receive a guide 2014 therein (and in some instances through it) such that the guide 2014 translates within the axial track 2050 between edges 2054 and 2056. The interaction between the guide 2014 and the axial tracks 2050 is described in more detail below.

[0234] FIG 24 illustrates a side view of a portion of the forceps 2000 in an open position with the outer shaft 2028 in phantom, in accordance with at least one example of the present disclosure. FIG 25 illustrates a side isometric view of a portion of the forceps 2000, in accordance with at least one example of the present disclosure. FIG 24 and FIG 25 are discussed together below. FIG 24 and FIG 25 illustrate the proximal, distal, upper, and lower directional indicators, with FIG 24 illustrating axis A1.

[0235] FIG. 25 shows that the guide 2014 can be secured to the outer shaft 2028, such as by insertion into bores 2060a and 2060b (only bore 2060b is visible in FIG. 25). The bore 2060 and guide 2014 can be disposed at a distal portion of the outer shaft 2028 relative to the forceps 2000. In some examples, the bore 2060 can be substantially coaxial and substantially perpendicular to axis A1. In such a case, the guide 2014 can be disposed within the bore 2060 and can be on an axis defined by the bore 2060 that is substantially perpendicular to axis A1. The bore 2060 is also substantially centered about the outer shaft 2028 and centers the guide 2014. In some examples, the bore 2060 can be offset (either upwards or downwards) from axis A1 and substantially perpendicular to axis A1. In another example, the bores 2060 can intersect a transverse plane defined in part by the axis A1, such that one bore is above the axis A1 and one is below, and the axis defined by the bores 2060 can pass through the axis A1 or can be offset therefrom in such a configuration. The axial track 2050 can be configured to match the orientation of the guide 2014, thereby allowing the inner shaft 2026 to translate relative to the guide 2014.

[0236] Figure 25 also shows that pivot pin 2018 can be disposed in and secured within bores 2062a and 2062b (only bore 2062b is visible in Figure 25). The orientation of bores 2062a and 2062b can be similar to any of those described above with respect to guide 2014 (aligned with axis A1, offset from axis A1, intersecting axis A1, etc.).

[0237] Guide 2014 may be mounted in bore 2060 and pivot pin 2018 may be mounted in bore 2062 to help prevent pins 2014 and 2018 from moving out of bores 2060 and 2062, respectively. Pins 2014 and 2018 may be secured to bores 2060 and 2062, respectively, using one or more of welding (such as laser welding), threaded connections, fasteners, adhesives, and the like.

[0238] In some examples of operation, when the inner shaft 2026 translates distally relative to the outer shaft 2028 to move the drive pin 2016 distally, move the flanges 2020 and 2022, and fully open the jaws 2010 and 2012, the distal translation of the inner shaft 2026 relative to the outer shaft 2028 can be limited by contact between the guide 2014 and the proximal edge 2054 of the axial track 2050 (shown in FIG. 24 ) of the inner shaft 2026, such that the guide 2014 can act as a distal stop (or distal travel stop) for the inner shaft 2026.

[0239] In some examples of operation, as the inner shaft 2026 translates proximally relative to the outer shaft 2028 to move the drive pin 2016 proximally and move the flanges 2020 and 2022 to fully close the jaws 2010 and 2012, the proximal translation of the inner shaft 2026 may be limited by contact between the guide 2014 and a distal edge 2052 of the axial track 2050 of the inner shaft 2026, such that the guide 2014 may act as a proximal stop for the inner shaft 2026. In another example, the proximal translation of the inner shaft 2026 may be limited by contact between the jaws 2010 and 2012 (such as their grip plates).

[0240] Contact between the guide 2014 and one or more upper edges 2052 may also help to limit downward movement of the inner shaft 2026. Similarly, contact between the guide 2014 and one or more lower edges 2054 may help to limit upward movement of the inner shaft 2026. Contact between the guide 2014 and the upper and lower edges 2052 and 2054, respectively, may also help to limit rotation of the inner shaft 2026 about axis A1 relative to the outer shaft 2028, such as when the end effector is rotated at the handle (discussed above). This may help to limit winding of the shafts 2028 and 2026, improving the performance of the forceps 2000 and helping to prevent breakage thereof.

[0241] The guide 2014 can also function as one or more of a proximal translation stop, a distal translation stop, a vertical movement limiter, and a rotation limiter for the inner shaft 2026, in an example where proximal translation of the inner shaft 2026 opens the jaws 2010 and 2012 and distal translation of the inner shaft 2026 closes the jaws 2010 and 2012. The guide 2014 can be any of the variations described above in terms of shape, size, and arrangement. In some examples, the guide 2014 can be engagable with the inner shaft 2026 to limit movement of the drive shaft 2026 relative to the outer shaft 2028 in a direction that is not parallel to the guide 2014. In some examples, the guide 2014 can be engagable with the inner shaft 2026 to limit movement of the drive shaft 2026 in a direction perpendicular to the guide 2014. Such limiting of vertical movement by the guide 2014 may limit movement of the shaft 2026 in a proximal direction and / or a distal direction and / or a vertically upward and / or a vertically downward direction.

[0242] FIG 26A shows a side view of a portion of a forceps 2000 with the inner and outer shafts 2026 and 2028 in phantom and the blade 2032 retracted, in accordance with at least one example of the present disclosure. FIG 26B shows a side view of a portion of a forceps 2000 with the inner and outer shafts 2026 and 2028 in phantom and the blade 2032 advanced. FIG 26A and FIG 26B also show the proximal, distal, upper, and lower directional indicators and axis A1. FIG 26A and FIG 26B are described below.

[0243] The forceps 2000 of Figures 26A and 26B may correspond to the forceps 2000 discussed above, with Figures 26A and 26B showing additional details of the blade 2032. For example, Figures 26A and 26B show that the blade 2032 may include an edge 2064, where the edge 2064 may be retracted from the jaws 2010 and 2012 when the blade 2032 is retracted, and where the edge 2064 may extend into the jaws 2010 and 2012 (along the trajectory of the jaws 2010 and 2012) when the blade 2032 is extended.

[0244] In some example operations, the blade 2032 can be translated distally into the tracks of the jaws 2010 and 2012 when the jaws are between the open and closed positions or when the jaws 2010 and 2012 are in the closed position. The blade 2032 can be used to cut tissue or other items between the jaws 2010 and 2012.

[0245] 26B also shows that the blade 2032 can include a blade track 2066 (or blade channel 2066), which can include a proximal edge 2068, an upper edge 2070T, and a lower edge 2070B. The track 2066 can extend along axis A1 the majority of the length of the blade 2032 and can have a height slightly greater than the diameter of the pins (2014, 2016, and 2018), allowing the blade 2032 to translate past the pins along axis A1.

[0246] The track 2066 can be configured to contact the guide 2014 to limit axial translation of the blade 2032 relative to the guide 2014 and outer shaft 2028. For example, the proximal edge 2068 (which can be rounded complementary to the guide 2014) can be configured to contact the guide 2014 to limit distal translation of the blade 2032 relative to the inner shaft 2026, outer shaft 2028, and jaws 2010 and 2012. In some examples, the blade track 2066 can be longer than the length of the outer slots 2044a and 2044b, such that the outer slots 2044a and 2044b do not limit translation of the blade 2032 relative to the inner shaft 2026, outer shaft 2028, and / or jaws 2010 and 2012.

[0247] Also, contact of one or more of the guide 2014, drive pin 2016, and pivot pin 2018 with the upper edge 2070T may help to limit downward and / or upward movement of the blade 2032 relative to the inner shaft 2026, the outer shaft 2028, and the jaws 2010 and 2012. Such contact may also help to limit rotation of the blade 2032, such as about axis A1. Similarly, contact of one or more of the guide 2014, drive pin 2016, and pivot pin 2018 with the lower edge 2070B may help to limit upward movement of the blade 2032 relative to the inner shaft 2026, the outer shaft 2028, and the jaws 2010 and 2012. Such contact may also help to limit rotation of the blade 2032. In some examples, the guide 2014 may be diametrically centered about the outer shaft 2028. In another example, the guide 2014 may be offset (upwardly, downwardly, and / or laterally) from the axis A1.

[0248] 27 illustrates an isometric view of a portion of forceps 2000 with inner shaft 2026 and outer shaft 2028 in phantom and jaws 2010 and 2012 removed, in accordance with at least one example of the present disclosure. FIG. 27 also illustrates proximal, distal, upper, and lower directional indicators.

[0249] The forceps 2000 of FIG. 27 can be consistent with the forceps 2000 described above, and additional details of the forceps are described with respect to FIG. 27. For example, FIG. 27 shows how the proximal edge 2068 of the blade track 2066 engages the guide (shaft pin) 2014 to limit distal translation of the blade 2032. FIG. 27 also shows a blade shaft 2072, which can be connected to a proximal portion of the blade 2032 at a location proximal to the guide 2014. The blade shaft 2072 can extend proximally from its connection to the blade 2032 through the outer shaft 2028 and the inner shaft 2026, where the shaft 2072 can be connected to a handle component as described above.

[0250] 28 shows an isometric view of a portion of a forceps 2000 with the inner shaft 2026 and the outer shaft 2028 shown in phantom, in accordance with at least one example of the present disclosure. FIG. 28 also shows proximal, distal, upper, and lower directional indicators, and axis A1.

[0251] The forceps 2000 of Fig. 28 may be consistent with the forceps 2000 discussed above, with additional details of the forceps being described with respect to Fig. 28. For example, Fig. 28 shows that the distal plug 2030 may be a distal plug securable to the outer tube 2028 between a pair of outer arms 2034 at a location proximal to the jaws 2010 and 2012.

[0252] In particular, the distal guide plug 2030 can include a body 2074, a sleeve 2076, and upper and lower protrusions 2078T and 2078B. The body 2074 can be sized for insertion within the outer shaft 2028, with the sleeve 2076 extending proximally into the outer shaft 2028. The protrusions 2078T and 2078B can extend laterally outward (upwardly and downwardly in some instances) from the body, where the protrusions 2078T and 2078B do not extend (or only minimally extend) beyond the outer surface of the outer tube 2028. Further details of the distal guide plug 2030 are described below.

[0253] 28 also shows that the guide 2014, drive pin 2016, and pivot pin 2018 can have diameters P1, P2, and P3, respectively. In some examples, the diameters P1, P2, and P3 can all be the same to help simplify the bill of materials and construction of the forceps 2000. However, in other examples, the diameters P1, P2, and P3 can be different.

[0254] FIG. 29A illustrates an isometric view of a portion of a forceps 2000 with the inner shaft 2026 and the outer shaft 2028 represented in phantom, in accordance with at least one example of the present disclosure. FIG. 29B illustrates an isometric view of a portion of a forceps 2000 with the inner shaft 2026 and the outer shaft 2028 represented in phantom. FIG. 29C illustrates an isometric view of a portion of a forceps 2000 with the inner shaft 2026 and the outer shaft 2028 represented in phantom. FIGs. 29A-C also illustrate proximal, distal, upper, and lower directional indicators, blade height BH, blade width BW, slot height SH, and slot width SW. FIGs. 29A-C are discussed simultaneously below.

[0255] The forceps 2000 of Figures 29A-29C can be consistent with the forceps 2000 described above, and additional details of the forceps 2000 are described with respect to Figures 29A-29C. For example, Figures 29A-29C show that protrusions 2078T and 2078B can extend upwardly and downwardly, respectively, from the body 2074 of the distal plug 2030. The protrusions 2078T and 2078B can be sized and shaped to nest into the recesses 2037 between the arms 2034, such that the protrusions 2078T and 2078B can form an interference fit with the outer shaft 2028 and help limit movement of the distal guide plug 2030 relative to the outer shaft 2028. This interference fit between the guide plug 2030 and the outer shaft 2028 can help secure the guide plug 2030 to the outer shaft 2028. The distal plug 2030 may additionally (or alternatively) be secured to the outer shaft 2028 using fasteners, threads, and / or adhesives.

[0256] 29A-C also show that the guide plug 2030 can include a braid channel 2080, a distal face 2082, and wire routing bores 2084 and 2086. Figures 29A-C also show that the braid channel 2080 can extend axially through the body 2074, such that the braid channel 2080 extends from a lower portion of the body 2074 such that the braid 2032 can be inserted into the braid channel 2080.

[0257] The slot height SH of the blade channel 2080 may be slightly greater than the blade height BH of the blade 2032 to allow movement of the blade 2032 through the blade channel 2080 while helping to limit upward and downward movement of the blade 2032 relative to the distal guide plug 2030 and thus the outer tube 2028. Similarly, the slot width SW of the blade channel 2080 may be slightly greater than the blade width BW of the blade 2032 to aid movement of the blade 2032 through the blade channel 2080 while helping to limit lateral movement of the blade 2032 relative to the distal guide plug 2030 and thus the outer tube 2028.

[0258] 29A-29C also show that the distal face 2082 of the guide plug 2030 may be curved to allow clearance for rotation of the flanges 2020 and 2022 during opening and closing of the jaws 2010 and 2012. Additionally, wire routing bores 2084 and 2086 may extend through the distal face 2082 and through the body 2074 and sleeve 2076 of the guide plug 2030, respectively. Each of the wire routing bores 2084 and 2086 may be sized and shaped to receive a wire (or conduit) therein and therethrough. Each of the wire routing bores 2084 and 2086 may be separated from the blade channel 2080 to help limit (or prevent or eliminate) interaction between the wire and the blade 2032.

[0259] FIG 29C also shows that the body 2074 of the guide plug 2030 can include channels 2088a and 2088b on opposing lateral outer surfaces of the distal plug 2030. The channels 2088 can each be a slot, track, channel, or flat configured to interface with an arm 2034 of the inner shaft 2026 such that the arm 2034 can translate through (or around) the distal plug 2030. The channels 2088 and other features of the guide plug 2030 are described in further detail below with respect to FIGS.

[0260] FIG 30A shows an isometric view of a portion of the forceps 2000 with the inner shaft 2026 in an extended position, in accordance with at least one example of the present disclosure. FIG 30B shows an isometric view of a portion of the forceps 2000 with the inner shaft 2026 in a retracted position. FIG 30C shows an end view of the guide plug 2030 of the forceps 2000. FIG 30A-B also show the proximal, distal, upper, and lower directional indicators. FIG 30C also shows the upper and lower directional indicators and axis A1. FIG 30A-C are discussed simultaneously below.

[0261] The forceps 2000 of Figures 30A-30C can be consistent with the forceps 2000 discussed above, with additional details of the forceps being described with respect to Figures 29A-29C. For example, Figure 30B illustrates how the arms 2034a and 2034b of the inner shaft 2026 can extend through channels 2088a and 2088b, respectively, around and beyond the guide plug 2030, allowing the inner shaft 2026 to move between a distal position (in one example, closed jaws 2010 and 2012) as shown in Figure 30B and a proximal position as shown in Figure 30A, where the inner shaft 2026 translates within the outer shaft 2028 to manipulate an end effector (such as jaws 2010 and 2012). That is, Figures 30A-30B show how arms 2034a and 2034b can be moved proximally around guide plug 2030 through (or around) channels 2088a and 2088b (e.g., when arms 2034 are positioned laterally medial to outer arm 2038) to move inner shaft 2026 to a proximal position.

[0262] 30C shows that the channels 2088 can each be flat, but the channels 2088 can be slots or other features that allow for extension of the arms 2034 beyond the guide plug 2030. In some examples, the channels 2088 can be on opposing lateral outer surfaces of the guide plug 2030.

[0263] FIG. 30C also illustrates that the blade channel 2080 can be offset laterally from the longitudinal axis A1 of the shafts (2026 and 2028), and that the wire routing bores 2084 and 2086 can be offset laterally from axis A1 on an opposite side from the blade channel 2080. In some examples, the distal plug 2030 can be oriented such that the blade channel 2080 is offset in another direction from axis A1, for example, upward or downward. FIG. 30C also illustrates that the wire routing bores 2084 and 2086 can be offset (upward and downward) from axis A1. However, in some examples, the wire routing bores 2084 and 2086 can be offset in another direction, such as laterally, from axis A1.

[0264] FIG. 30C also clearly shows how, during assembly of the forceps 2000, a blade channel 2080 may extend from (or through) the end of the lower portion of the body 2074 to allow the blade 2032 to be inserted into the blade channel 2080.

[0265] 31A shows an end view of a guide plug 2530 of a forceps, in accordance with at least one example of the present disclosure. The guide plug 2530 may be similar to the guide plug 2030 described above, except that the blade channel 2580 of the guide plug 2530 may merge with the wire routing bores 2584 and 2486 such that the wire routing bores 2584 and 2486 are still configured to hold wires therein. Such a design may help simplify the manufacture of the guide plug 2530, which may be a small component with tight tolerances. Any of the forceps described above or below may be modified to include the guide plug 2530.

[0266] 31B illustrates an end view of a guide plug 2630 of a forceps, in accordance with at least one example of the present disclosure. The guide plug 2630 can be similar to the guide plug 2030 described above, except that the blade channel 2680 of the guide plug 2630 can terminate within the body 2674. That is, the blade channel 2680 does not extend from a lateral, top, or bottom side of the guide plug 2630. Such a blade channel can help limit downward movement of the blade within the guide plug 2030. Any of the forceps described above or below can be modified to include a guide plug 2630.

[0267] FIG. 31C illustrates an end view of a guide plug 2730 of a forceps, according to at least one example of the present disclosure. FIG. 31C also illustrates top and bottom directional indicators. The guide plug 2730 may be similar to the guide plug 2030 described above, except that the blade channel 2780 of the guide plug 2730 may include a protrusion 2784 extending inwardly across a portion of the blade channel 2780 (such as a lower or lateral outer portion) to provide a reduced size opening 2782 of the blade channel 2780 at the outer portion of the blade channel 2780. Such a blade channel may allow a blade to be inserted into the blade channel 2780 through a lower portion of the guide plug 2730. The protrusion 2784 may help limit the lower portion of the blade channel 2780 from moving or folding laterally inwardly during manipulation of the forceps and pinching the blade within the slot 2780, which may help improve use of the forceps 2000 during surgery, for example. Any of the forceps described above or below can be modified to include a guide plug 2730.

[0268] Figure 32A shows a side view of a portion of forceps 2700, in accordance with at least one example of the present disclosure, and Figure 32B shows a perspective view of a portion of forceps 2700. Figures 32A-B are discussed simultaneously below.

[0269] The forceps 2700 can include an upper jaw 2710 (including a flange 2720), a lower jaw 2712, a guide 2714, a drive pin 2716, a pivot pin 2718, an inner shaft 2726, and an outer shaft 2728. The outer shaft 2728 can include outer arms 2736a and 2736b.

[0270] 32A and 32B can be similar to the forceps 2000 described above, except that only the upper jaw 2710 moves relative to the lower jaw 2712, where the lower jaw 2712 can be fixed relative to the inner shaft 2726 and the outer shaft 2728. In some examples, the upper jaw 2710 can be fixed and the lower jaw 2712 can be movable.

[0271] The forceps 2700 may include any of the features described above with respect to any of the other forceps, but differs in that only the flange 2720 of the upper jaw 2710 is driven by a drive pin 2716 to move the jaw 2710 between an open and closed position as the jaw pivots about a pivot pin 2718. Similarly, any of the forceps described above or below may be modified to include the components of the forceps 2700.

[0272] Figure 33A shows a side view of a portion of a forceps 2800, in accordance with at least one example of the present disclosure, and Figure 33B shows a perspective view of a portion of the forceps 2800. Figures 33A-B are discussed simultaneously below.

[0273] The forceps 2800 can include an upper jaw 2810 (including flanges 2820a and 2820b), a lower jaw 2812 (including flanges 2822a and 2822b), a guide 2814, a drive pin 2816, a pivot pin 2818, an inner shaft 2826, and an outer shaft 2828. The outer shaft 2828 can include outer arms 2836a and 2836b.

[0274] 33A and 33B may be similar to the forceps described above, except that flange 2822 may be interlaced with flange 2820, allowing the jaw assemblies (2010 and 2012) to be the same components, reducing costs. In such an example, blade 2832 may be disposed between one of flanges 2822 and one of flanges 2820. Forceps 2800 may include any of the features described above with respect to any of the other forceps. Similarly, any of the forceps described above or below may be modified to include the components of forceps 2800.

[0275] Fig. 34A shows a side view of a portion of a forceps 2900, in accordance with at least one example of the present disclosure. Fig. 34B shows a perspective view of a portion of the forceps 2900. The forceps 2900 may include any of the features described above with respect to the other forceps.

[0276] FIG 35A shows a side view of forceps flange 3022A, FIG 35B shows a side view of forceps flange 3022B, and FIG 35C shows a side view of forceps flange 3022C, in accordance with at least one example of the present disclosure. FIG 35A-C also show proximal, distal, upper, and lower directional indicators. FIG 35A-C are discussed simultaneously below.

[0277] 35A-C show flanges 3022A, 3022B, and 3022C, respectively, which may each include a pivot bore 3090 extending in or through the flange 3022. The pivot bore 3090 is configured to receive a pivot pin (e.g., pivot pin 2018) therethrough to secure the flange 3022 to the outer shaft such that the flange 3022 may pivot about the outer shaft.

[0278] 35A-35C also show curved proximal portions 3092 adjacent the top edges 3094 of flanges 3022A, 3022B, and 3022C. The curved proximal portions 3092 may each be rounded or curved (or otherwise shaped or contoured) to reduce lateral stretching of the flanges 3022 when the jaws are in the open position. The curved proximal portion 3092 of flange 3022A may have a relatively small radius, while the curved proximal portion 3092 of flange 3022C may have a relatively large radius that is not concentric with the curvature of the proximal end 3093 of the track 3042 of flange 3022C. That is, the center of curvature C1 of the proximal end 3093 may be non-concentric with the center of curvature C2 of the curved proximal portion 3092. The relatively large radius of the curved proximal portion of the flange 3022C may further help reduce lateral stretching of the flange 3022C when the jaws are in the open position.

[0279] 35A-35C also show that the top portion of the flange may be removed to further limit lateral extension of the flange 3022 when the jaws are in the open position. For example, the lip 3094 of FIGS. 35B and 35C may be moved laterally (or downward) approximately 0.5 millimeters as shown in FIG. 35A. In another example, the lip 3094 may be moved more or less downward depending on the material and size and shape of the flange 3022, e.g., based on the stress applied to the flange from its manipulation. The forceps of FIGS. 35A-35C may include any of the features described above with respect to any of the other forceps. Similarly, any of the forceps described above or below may be modified to include the components of the forceps of FIGS. 35A-35C.

[0280] FIG 36A shows a side view of a portion of forceps 3000A, FIG 36B shows a side view of a portion of forceps 3000C, and FIG 36C shows a side view of a portion of forceps 3000C, in accordance with at least one example of the present disclosure. FIG 36A-C also show proximal, distal, upper, and lower directional indicators. FIG 36A-C are discussed simultaneously below.

[0281] The forceps 3000A can include the flange 3022A of FIGURE 35A and various components similar to the forceps described above, such as an upper jaw 3010, a lower jaw 3012, a drive pin 3016, a pivot pin 3018, an inner shaft 3026, an outer shaft 3028, and an outer arm 3036. FIGURE 36A shows how a proximal rounded portion 3092A of the flange 3022A extends laterally outward (or upward) beyond the outer shaft 3028 when the jaws 3010 and 3012 are in the open position.

[0282] 36B and 36C illustrates how the lateral extension of the flanges 3022C beyond the outer shaft 3028 can be reduced by the curved proximal portion 3092 of the flanges 3022C. Such reduction in lateral extension can help to reduce contact between the flanges 3020 and 3022 and tissue within the body lumen, and therefore can help to reduce interference with tissue by the flanges 3020 and 3022.

[0283] The proximal rounded portion of the flange is described in further detail below with respect to forceps 2000. Forceps 3000 may include any of the features described above with respect to any of the other forceps. Similarly, any of the forceps described above or below may be modified to include the components of forceps 3000.

[0284] FIG 37A illustrates a side view of a portion of a forceps 3200, in accordance with at least one example of the present disclosure. FIG 38 illustrates a side view of a portion of a forceps 3300, in accordance with at least one example of the present disclosure. FIG 38 illustrates a side view of a portion of a forceps 3300, in accordance with at least one example of the present disclosure. FIG 37A-FIG 38 are discussed simultaneously below.

[0285] The forceps 3200 can include an upper jaw 3210, a lower jaw 3212, and an outer shaft 3228. The lower jaw can include a flange 3222. Similarly, the forceps 3300 can include an upper jaw 3310, a lower jaw 3312, and an outer shaft 3328. FIGS. 37A and 37B show how a rounded proximal portion 3292 of the flange 3222 of the lower jaw 3212 can reduce lateral extension of the flange beyond the outer surface of the outer shaft 3228 over a less rounded proximal portion 3392 of the flange 3322.

[0286] Fig. 39A shows a side view of a portion of a forceps 3400, in accordance with at least one example of the present disclosure. Fig. 39B shows a side view of a portion of a forceps 3500, in accordance with at least one example of the present disclosure. Fig. 39C shows a side view of a portion of a forceps 3600, in accordance with at least one example of the present disclosure. Figs. 39A-C are discussed simultaneously below.

[0287] Figure 39A shows a forceps 3400 that includes an upper jaw 3410 in two positions indicated by 3410a and 3410b, which includes a flange 3420 in two positions indicated by 3420a and 3420b. The forceps may also include a lower jaw 31484, which may be fixed, and an outer shaft 3428. Also shown in Figure 39A are distances E1, E2, O1, and O2.

[0288] 39A shows that when the upper jaw 3410 is in a first open position at 3410a, the distance between the jaws can be O1, which can be 14.5 millimeters in one example. In a second open position at 3410b, the distance between the jaws can be O2, which can be 16.5 millimeters in one example, a difference of about 2 millimeters. When the jaw 3410 is in a first open position at 3410a, the flange 3420 can be in a first position 3420a, which can have a distance E1 of about 2.3 millimeters from the outer shaft 3428 in one example. When the jaw 3410 is in a second open position at 3410b, the flange 3420 can be in a second position 3420b, which can have a distance E2 of about 3 millimeters from the outer shaft 3428 in one example, a difference of about 0.7 millimeters between the positions.

[0289] This means that a 0.7 millimeter difference in flange extension corresponds to a 2.0 millimeter difference in opening, and a larger opening between the jaws 2010 and 2012 may provide a better range of operation for the forceps 3400. However, having a flange that extends beyond the outer surface of the outer shaft 3428 more than necessary is undesirable as the flange 3420 may engage surrounding tissue. Thus, as shown in FIG. 39C, the flange 3620 may have a proximal rounded portion 3692 that is configured to reduce the amount that the flange 3620 extends beyond the outer surface of the outer shaft 3628 compared to the flange 3520 of the forceps 3500 of FIG. 39B, which may extend relatively further outward than the flange 3620 of the forceps 3600 of FIG. 39C.

[0290] FIG 40A shows a side view of the jaw 3710, according to at least one example of the present disclosure. FIG 40B shows a side view of the jaw 3710. FIG 40C shows an end view of the jaw 3710. FIG 40D shows an isometric view of the jaw 3710. FIG 40B and FIG 40C show an axis A1, and FIG 40C shows a vertical plane P1. FIG 40A-FIG 40D are discussed together below.

[0291] The jaws 3710 may be similar to another jaw described above, and may include flanges 3720a and 3720b including tracks 3740a and 3740b and pivot pin bore 3790. FIGS. 40A-40D also show that the jaws 3710 may have an outer shell 3795 that may be relatively round and smooth to help limit snagging or catching on tissue. FIG. 40B also shows that the jaws 3710 may be curved relative to axis A1. FIGS. 40B and 40D also show an upper wire 3738 that may connect to and power an electrode of the jaws 3710. The jaws 3710 may include any of the features described above with respect to any of the forceps. Similarly, any of the forceps described above or below may be modified to include the components of the jaws 3710.

[0292] FIG 41A shows an isometric view of the jaw 3712, according to at least one example of the present disclosure. FIG 41B shows a side view of the jaw 3712. FIG 41C shows a side view of the jaw 3712. FIG 41D shows an end view of the jaw 3712. FIG 41C and FIG 41D show the axis A1. FIG 41A-FIG 41D are discussed simultaneously below.

[0293] The jaw 3712 may be similar to the other jaws described above, where the jaw 3712 may include flanges 3722a and 3722b having tracks 3742a and 3742b and a pivot pin bore 3790. FIGS. 40A-40D show that the jaw 3710 may have an outer shell 3797 that may be relatively rounded and smooth and may help limit (or prevent or eliminate) snagging or catching of the jaw 3712 on tissue. FIG. 41C also shows that the jaw 3710 may be curved relative to axis A1. FIG. 41C further shows a lower wire 3799, which may connect to an electrode of the jaw 3712 to provide power thereto.

[0294] FIG. 41A also shows that the plate 3724 of the jaw 3712 can include a blade slot 3725 that can extend along the plate 3724 of the jaw 3712 and can be configured to receive a blade (such as blade 2032) therein. In some examples, the blade slot 3725 can be curved with the profile of the jaw 3712. Each jaw described above or below can include such a blade slot. In some examples, the jaw 3710 can include a blade slot 3723 that can be complementary to the blade slot 3725. That is, the blade slots 3725 and 3723 can be parallel such that each of the jaws 3710 and 3712 (when operating together) can receive a blade therein when the jaws 3710 and 3712 are in a closed or partially closed position.

[0295] The jaws 3712 may include any of the features described above with respect to any of the other forceps. Similarly, any of the forceps described above or below may be modified to include the components of the jaws 3712.

[0296] FIG. 42 illustrates a side view of a portion of the forceps 2000 in a closed position, with the inner shaft 2026 and the outer shaft 2028 represented in phantom, in accordance with at least one example of the present disclosure. FIG. 43 illustrates a side view of a portion of the forceps 2000 in an open position, with the inner shaft 2026 and the outer shaft 2028 represented in phantom. FIG. 44 illustrates a side view focused on a portion of the forceps 2000. FIG. 42 illustrates the portion indicators C1-C1 and C2-C2. FIGs. 42-44 illustrate the proximal and distal directional indicators. FIG. 44 also illustrates the angle θ. FIGs. 42-44 are discussed simultaneously below.

[0297] The forceps 2000 of Figures 42-44 can be consistent with the forceps 2000 described above, and further details are described below with respect to Figures 42-44. For example, Figures 43 and 44 show that the flange 2020b can include a track 2040b, a rounded proximal portion 2092, an outer (or lower) edge 2094, an upper (or inner or upper) edge 2100, and a proximal inner portion 2102. The track 2040b can include a proximal end 2104.

[0298] The rounded proximal portion 2092 can be connected to a lower edge 2094 and to the proximal inner portion 2012, e.g., proximal to the jaw pivot, which can be defined by a pivot pin 2018. The proximal inner portion 2102 can be connected to an upper (or inner) edge 2100. The proximal end 2104 can be a portion of the slot 2040b, which can include an end of the slot 2040b. The proximal end 2104 can be disposed near the rounded proximal portion 2092.

[0299] The rounded proximal portion 2092 may be shaped to be rounded or curved, similar to the proximal inner portion 2102. The rounded proximal portion 2092 may be curved or have a laterally radiused edge (as shown in FIG. 44 ) to help limit the rounded proximal portion 2092 from extending beyond the outer shaft 2028 when the jaws 2010 and 2012 are in the open position (or between the open and closed positions). That is, one or more of the proximal portions 2092 of the flanges 2020 and 2022 may be shaped to limit the proximal portion 2092 from extending laterally beyond the arms 2038 of the outer shaft 2028, which may help to limit engagement of the flanges 2020 and 2022 with surrounding tissue during a procedure. In some examples, such a rounded proximal portion 2092 may be used with only one flange 2020 and one flange 2022.

[0300] In some examples, the rounded proximal portion 2092 can be curved or have a radiused edge that is greater than the radius of the proximal inner portion 2102. In other words, the inner proximal portion 2102 can be rounded at a radius that is less than the radius of the rounded proximal portion 2092. In some examples, the rounded proximal portion 2092 can be disposed near the track 2040. The rounded proximal portion 2092 can be profiled to limit stresses in the flange 2020, where stresses can be generated by interaction between the track 2040 (flange 2020) and the inner shaft 2026, for example, via the drive pin 2016.

[0301] The proximal end 2104 of the track 2040 may be the terminus of the track 2040 and may have a curved or radiused shape. In some examples, the rounded proximal portion 2092 may have a curvature that is not concentric with the curvature of the proximal end 2104 of the track 2040. In some examples, the rounded proximal portion 2092 may have as large a radius as possible to reduce the stretch (e.g., reduced radial stretch) of the flange 2020 beyond the outer shaft 2028 without reducing the strength of the flange 2020 adjacent the track 2040 below that required for normal operation of the flange 2020 (e.g., to withstand forces applied by the drive pin 2016). FIG. 42 also illustrates that when the jaws 2010 and 2012 are in the closed position, the flanges 2020 and 2022 do not extend laterally beyond the outer shaft 2028.

[0302] In some examples, the profile of the proximal portion 2092 can be configured to maintain a minimum thickness between the track 2040 and the proximal portion 2092. In some examples, the minimum thickness can be between 0.1 millimeters and 1.5 millimeters. In another example, the minimum thickness can be between 0.3 millimeters and 1 millimeter. In another example, the minimum thickness can be 0.7 millimeters.

[0303] In some examples, the profile of the proximal portion 2092 of the flange 2020 may include an edge 2103 having an arc that is tangent to the outer edge 2094. In some examples, the arc of the edge 2103 may be eccentric with the arc of the proximal end 2104 of the track 2040b. In some examples, the arc of the edge 2103 may have a larger radius of curvature toward the laterally inner portion (toward the inner rounded portion 2102) than toward the laterally outer portion (toward the rounded proximal portion 2092) when the flanges 2020 and / or 2022 are in an open position (or not in a closed position). In any of the examples discussed herein, the flange 2020 may be symmetrical about one or more axes.

[0304] 44 also illustrates angle θ, which may be the angle formed between the top surface of the outer arm 2034 and the flange 2022b. (The flange 2020 may form a similar angle with the bottom surface of the outer arm 2034.) The rounded proximal portion 2092 of the flange 2022 may at least partially define the angle θ. In some examples, the rounded proximal portion 2092 may have a curvature to limit (or prevent or eliminate) the angle θ from becoming acute, such as when the flange 2022 (or flange 2020) is in an open position. Minimizing the angle θ may help limit the pinching or scissoring of tissue between the flange 2022 and the outer arm 2034 during opening and closing of the jaws 2010 and 2012. Additionally, the proximal inner portion 2102 can be prevented from extending laterally (as described above) beyond the top surface of the outer arm 2034 (e.g., by the placement of the track 2042), which can further help limit undesirable pinching or scissoring of tissue during opening and closing of the jaws 2010 and 2012. In some examples, the transition between the proximal inner portion 2102 and the proximal inner portion 2102 can be curved or rounded to further prevent scissoring.

[0305] Figure 45 shows a cross-sectional view of a portion of the forceps 2000 across section C1-C1 of Figure 42. Figure 46 shows a cross-sectional view of a portion of the forceps 2000 across section C2-C2 of Figure 42. Figure 47 shows a side view of a portion of the forceps 2000 with the inner shaft 2026 and outer shaft 2028 represented in phantom. Figures 45-47 are discussed together below.

[0306] The forceps 2000 of Figures 45 and 46 may conform to the description of the forceps 2000 discussed above. Figures 45 and 46 show details of the chamfers on the flanges 2020 of the jaws 2010. In particular, Figures 45 and 46 show the flanges 2020a, 2020b, 2022a and 2022b. Also shown are the inner shaft 2026 including arms 2034a and 2034b, and the outer shaft 2028 including arms 2034a and 2034b and including the outer surface 2106.

[0307] Additionally, the blade 2032 is shown in the blade channel 2080 of the guide plug 2030 offset from axis A1, and the wire routing bores 2084 and 2086 of the guide plug 2030 are shown offset from axis A1 on opposite sides of the blade 2032. FIG. 45 also shows the drive pin 2016, and FIG. 46 shows the shaft pin 2014. FIGs. 45 and 46 also show further details of the flanges 2020a and 2020b, such as the upper edges 2102a and 2102b, respectively, the outer surfaces 2108a and 2108b, respectively, and the chamfers 2110a and 2110b, respectively.

[0308] FIG 45 also shows diameter D1, which may be the inner diameter of the outer shaft 2028, and diameter D2, which may be the outer diameter of the inner shaft 2026. FIG 45 shows how diameter D2 is smaller than diameter D1, and how the inner shaft 2026 and the arms 2034 of the inner shaft 2026 fit within the outer shaft 2028, allowing relative translation of the inner shaft 2026 to the outer shaft 2028.

[0309] 45 and 46, the chamfer 2110a can extend between the outer surface 2108a and the upper edge 2102a. Similarly, the chamfer 2110b can extend between the outer surface 2108b and the upper edge 2102b. The chamfer 2110 can be sized and shaped to limit the flange 2020 of the jaws 2010 from extending laterally beyond the outer surface of the outer shaft 2028 when the jaws 2010 and 2012 are in a closed position, which helps reduce the overall profile of the end effector 2002, which helps with easier insertion of the end effector 2202 into a cannula and / or opening.

[0310] In some examples, the one or more chamfers 2110 can be a bevel extending between the upper edge 2102 and the outer surface 2108. In another example, the chamfer 2110 can be a curved or notched surface of the flange 2020 and configured to limit the extension of the flange 2020 beyond the outer surface 2106 of the outer shaft 2028. In some examples, the one or more chamfers 2110 can be rounded.

[0311] 47, the chamfer 2110 can be placed against the track 2040 to expand the thickness of the flange 2020 adjacent the distal end of the track, which can help increase the strength of the flange 2020 against which the drive pin 2016 can apply a force to the track 2040. In another example, if the track 2040 is inverted, the chamfer 2110 can be placed against the track 2040 to expand the thickness of the flange 2020 adjacent the distal end 2104 of the track 2040.

[0312] In some examples, one or more of the flanges 2022a and 2022b may include a chamfered outer edge configured to limit extension of the flange 2022 beyond the outer surface 2106 of the outer shaft 2028. In examples in which the flanges 2020 and 2022 are staggered, either one of the flanges 2020 and 2022 may include a chamfered edge configured to limit extension of the flange 2022 beyond the outer surface 2106 of the outer shaft 2028.

[0313] 46, the chamfers 2110a and 2110b may be spaced further from the outer surface at a location more proximal to the flanges 2020a and 2020b, respectively. That is, the chamfers 2110a and 2110b may define an edge that extends substantially axially along the flange 2020 when the jaws 2010 and 2012 are in the closed position. The edge (chamfer 2110) may be located laterally inward (or radially inward in some examples) of the outer surface 2106 of the outer tube 2028.

[0314] In some examples, the chamfer 2110 (or chamfered edge) can be angled laterally inward (or radially inward) from an axially distal position to an axially proximal position. In operation of the forceps 2000, when a large force is applied to compress the jaws 2010 and 2012, the proximal portions of the flanges 2020 and 2022 can extend radially outward beyond the outer surface of the outer shaft 2028. As a result, during removal of the forceps from the trocar while grasping tissue, the flanges may engage the trocar, which can complicate the removal procedure. The chamfer 2110 (or chamfer edge) being angled laterally inward (or radially inward) from an axially distal position to an axially proximal position (or chamfer edge 2110 with a rearward rake) can help reduce lateral stretching of the flanges 2020 and 2022 over the outer shaft 2028 caused by application of large forces to the actuator, which can help avoid engagement with the trocar (or tissue or another component) when removing the forceps 2000 from the body cavity.

[0315] 48 illustrates a cross-sectional view of a portion of forceps 4000 taken across section 45-45 of FIG. 42, in accordance with at least one example of the present disclosure. Forceps 4000 can be similar to those described above, in that the forceps can include jaws 4010 and 4012 including flanges 4020 and 4022, respectively. Forceps 4000 can also include an inner shaft 4026 including inner arms 4034a and 4034b, and forceps 4000 can include an outer shaft 4028 including outer arms 4036a and 4036b.

[0316] 48 also illustrates that the flanges 4020 and 4022 can form a channel therebetween, which can be configured (e.g., sized and shaped) to receive the blade 4032 and the wires 4098 and 4099 therethrough. In some examples, the wires 4098 and 4099 can extend axially through the first and second sets of flanges 4020 and 4022 at a location laterally inboard of the first and second sets of flanges 4020 and 4022.

[0317] One wire, such as wire 4098, can be above the axis A1 of the shaft and another wire, such as wire 4099, can be below the axis A1. In some examples, wire 4098 can be above the drive pin (routed to the upper jaw 4010) and wire 4099 can be below the drive pin (routed to the lower jaw 4012). In some examples, the blade 4032 can be offset (e.g., laterally offset) from the axis A1 and the wires 4098 and 4099 can be offset (e.g., laterally offset) from the axis A1 on an opposite side of the blade 4032. In some examples, axis A1 can be the central axis of the inner shaft 4026 where the blade 4032 can extend through the inner shaft 4026 along axis A1.

[0318] FIG. 49 illustrates a cross-sectional view of a portion of forceps 4100 taken across section 46-46 of FIG. 42, in accordance with at least one example of the present disclosure.

[0319] The forceps 4100 may be similar to the other forceps described above in that the forceps may include jaws 4110 and 4112 including flanges 4120 and 4122, respectively. The forceps 4100 may also include an inner shaft 4126 including inner arms 4134a and 4134b, and the forceps 4100 may include an outer shaft 4128 including outer arms 4136a and 4136b.

[0320] 49 also shows that the flanges 4120 and 4122 can form a channel therebetween that can receive the blade 4132. The flanges 4120 and 4122 can also form a lateral outer channel for the wires 4198 and 4199, respectively, such that the wire 4198 can be disposed laterally outboard of the flanges 4120 and 4122 and laterally inboard of the arms 4134 and 4136. One wire, such as wire 4198, can be above the axis A1 of the shaft routed to the upper jaw 4110 and another wire, such as wire 4199, can be below the axis A1 routed to the lower jaw 4112. In some examples, the wire 4198 can be above the drive pin 4116 and the wire 4199 can be below the drive pin 4116. In some examples of this configuration, the flanges 4120 and 4122 can be interlaced.

[0321] FIG. 50 illustrates a side isometric view of a portion of a forceps 2000, in accordance with at least one example of the present disclosure. The forceps 2000 can be consistent with the forceps 2000 described above. FIG. 50 illustrates that a guide tube 2112 (or lumen 2112) can be disposed within the inner shaft 2026 and the outer shaft 2028 and can extend through the outer shaft 2028 and the inner shaft 2026 between the end effector 2002 and the handle 2001. In particular, the guide tube 2112 can extend from a distal location just outside the proximal edge of the blade 2032 when the blade is in a retracted position and can extend proximally to a clip (such as clip 1056) or a distal location to hold a slider block (such as drive body 1052) to the drive shaft or inner shaft 2026.

[0322] Fig. 51A shows an end isometric view of a portion of forceps 2000, in accordance with at least one example of the present disclosure. Fig. 51B shows an end isometric view of a portion of forceps 2000. Figs. 51A and 51B are described simultaneously below.

[0323] The forceps 2000 can be consistent with the description above, with Figures 51A and 51B showing additional details. For example, Figures 51A-51B show a guide tube 2112 and can include a body 2114 defining a blade bore 2116 and a wire routing bore 2118. Figures 51A and 51B further show proximal and distal directional indicators and axis A1.

[0324] The body 2114 can extend along the axis A1 and in some examples can be substantially cylindrical, but in other examples can be other shapes, e.g., an elliptical prism, a rectangular prism, a hexagonal prism, an octagonal prism, etc. The body 2114 can be configured, e.g., sized and shaped, to be complementary with the interior bore of the inner shaft 2026 and form a pneumatic seal with the inner shaft 2026.

[0325] The blade bore 2116 and the wire routing bore 2118 may each be a bore extending axially through the body 2114 along the axis A1. The blade bore 2116 may be sized and shaped to receive the shaft 2072 of the blade 2032 therethrough and may be configured to allow translation of the shaft 2072 within the guide tube 2112 to allow the blade 2032 to be manipulated from the handle 2001 such that the blade 2032 may translate within the blade channel of the jaws 2010 and 2012. The blade bore 2116 may also be sized relative to the blade shaft 2072 such that a pneumatic seal, or seal, may be formed between the blade bore 2116 and the blade shaft 2072 to help reduce the migration of pressurized air or gas through the body 2114.

[0326] The wire routing bore 2118 can be sized and shaped to receive one or more wires or conduits therethrough, allowing the conduits to extend from the handle 2001 to the electrodes of the jaws 2010 and 2012. In some examples, the guide tube 2112 can be formed of a non-conductive material. In some examples, the guide tube 2112 can be formed by extrusion. The wire routing bore 2118 can also be sized relative to the conduit(s) such that a pneumatic seal or seals can be formed between the wire routing bore 2118 and the conduit(s) to help reduce the migration of pressurized air or gas through the body 2114.

[0327] FIG 52A shows an end isometric view of the guide tube 2112 and blade shaft 2072, in accordance with at least one example of the present disclosure. FIG 52B shows an end view of the guide tube 2112e. Additionally, FIG 52A and FIG 52B show the proximal and distal directional indicators and axis A1. FIG 52A and FIG 52B are discussed simultaneously below.

[0328] The guide tube 2112 may be consistent with the description above, with FIGS. 52A and 52B showing additional details of the guide tube 2112. For example, FIGS. 52A-52B show that the blade bore 2116 and / or wire routing bore 2118 of the guide tube 2112 may extend axially through the body 2114 of the guide tube 2112. In some examples, one or more of the blade bore 2116 and the wire routing bore 2118 may extend through the guide tube 2112 in an axial direction parallel to the axis A1. In some examples, the blade bore 2116 may be offset from the axis A1. In some examples, the wire routing bore 2118 may be offset from the axis A1 to the opposite side of the blade channel, as shown in FIG. 52B.

[0329] In one example, the guide tube 2112 can include a second wire routing bore extending therethrough, the second wire routing bore configured to receive a second conduit therethrough. The second wire routing bore can be offset from axis A1 on an opposite side of the blade channel 2116. The second wire routing bore can be offset of the longitudinal axis, the second wire routing bore can be offset on an opposite side of the longitudinal axis from the wire routing bore.

[0330] 53 shows an exploded view of the jaw 2012. The jaw 2012 can include a grip plate 2024 (including a blade slot 2025), a wire 2099, a frame 2120 (including flanges 2022a and 2022b), an overmold 2122 (including a blade slot 2125), and a support 2124.

[0331] The jaws 2012 may be consistent with the description above, with FIG. 53 showing additional details of the jaws 2012. For example, FIG. 53 shows that the overmold 2122 may include a blade slot 2125 that may be aligned with the blade slot 2025 of the grip plate 2024 when the overmold 2122 is secured to the grip plate 2024 (e.g., when the overmold 2122 is overmolded onto the frame 2120 and grip plate 2024). FIG. 53 also shows that the frame 2120 may include a slot 2126 into which the support 2124 may be received. The support 2124 helps support the grip plate 2024 on the frame 2120.

[0332] 53 also shows that the grip plate 2024 can include teeth 2128 that can define recesses 2130. The recesses 2130 can be disposed on a side edge of the grip plate 2024. The recesses 2130 can be configured such that the material of the overmold 2122 can infiltrate (or fill) the recesses (or spaces or gaps) 2130 such that the grip plate 2024 is secured to the overmold 2122. The grip plate 2024 can also be (or include) an electrode that can be electrically connected to a wire (or conduit) 2099.

[0333] Note Although the illustrated examples of medical devices are shown and described in this disclosure with respect to forceps, the features may be used in other medical devices other than forceps for controlling end effectors used in diagnosis, treatment, or surgery. The representation or description of a forceps is provided primarily for illustrative purposes to disclose the features of the various examples.

[0334] While the forceps shown in the example may be an electrosurgical device, the forceps may be any type of medical device that facilitates mechanical and / or electrical actuation of one or more end effectors or other elements disposed distally from a handpiece having one or more actuation systems. The described actuation systems may extend, retract, or rotate one or more shafts to produce this result and may be used to effect an action on another medical device (e.g., a medical instrument).

[0335] The directional descriptors described herein are used in conjunction with their normal and conventional use in the art. For example, proximal, distal, lateral, superior, inferior, top and bottom may be used to describe a device with its longitudinal axis oriented parallel to the ground when the device is in an upright position. The proximal direction refers to the direction toward the user end of the device, and the distal direction refers to the direction toward the patient end of the device.

[0336] Relative terms used herein, such as "about" or "substantially," may be used to indicate a possible variation of ±10% from the stated numerical value, or manufacturing variation.

[0337] As described throughout this disclosure, the components and assemblies can be operatively connected to one another and interact with one another in ways that provide improved operation, more compact and simple designs, lower costs, and better user satisfaction than conventional medical devices.

[0338] The above detailed description includes references to the accompanying drawings, which form a part of the detailed description. The drawings show, by way of illustration, specific embodiments in which the invention may be practiced. These embodiments are also referred to herein as "examples." Such examples may include elements in addition to those shown or described. However, the inventors also contemplate examples in which only those elements shown or described are provided. Moreover, the inventors also contemplate examples in which any combination or permutation of the shown or described elements (or one or more aspects thereof) is used with a particular example (or one or more aspects thereof) or with another example (or one or more aspects thereof) shown or described herein.

[0339] In this document, the terms "a" or "an" are used as is common in patent documents to include one or more, regardless of other instances or usages of "at least one" or "one or more." In this document, the term "or" is used to refer to non-exclusive or, unless otherwise specified, "A or B" includes "A but not B," "B but not A," and "A and B." In this document, the terms "including" and "in which" are used as the plain English equivalents of the terms "comprising" and "wherein," respectively. Also, in the appended claims, the terms "including" and "comprising" are open-ended, i.e., systems, apparatus, articles, compositions, methods, or processes that include elements in addition to those elements after such terms are recited in the claim are deemed to be within the scope of the claim. Moreover, in the appended claims, the terms "first," "second," and "third" are used merely as labels and are not intended to impose numerical requirements on their objects.

[0340] In the event of any inconsistent usage between this document and any document so incorporated by reference, the usage in this document shall control. In this document, the terms "including" and "in which" are used as the plain English equivalents of the terms "comprising" and "wherein," respectively. Also, in the appended claims, the terms "including" and "comprising" are intended to be open-ended, i.e., systems, apparatus, articles, compositions, methods, or processes that include elements in addition to those elements after such terms are recited in the claim are deemed to be within the scope of the claim.

[0341] The above description is intended to be illustrative, not limiting. For example, the above examples (or one or more aspects thereof) may be used in combination with each other. Alternative embodiments may be used by those of skill in the art upon reviewing the above. The Abstract is provided in accordance with 37 C.FR §1.72(b) to enable the reader to quickly ascertain the nature of the technical disclosure. The Abstract is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims. Moreover, in the above Detailed Description, various features may be grouped together to streamline the disclosure. This should not be construed as intending that any unclaimed disclosed feature is essential to any claim. Rather, inventive subject matter may reside in less than all features of a particular disclosed embodiment. Thus, the appended claims are hereby incorporated into the Detailed Description, with each claim standing on its own as an individual embodiment, and such embodiments can be combined with each other in various combinations or permutations. The scope of the invention should be determined with reference to the appended claims, along with the full scope of equivalents to which such claims are entitled.

Claims

1. Frame and a motion transmission assembly coupled to the frame, the motion transmission assembly comprising: a body having a passage therethrough; a biasing element coupled to the body; a drive shaft extending completely through the body via the passageway, wherein the body and the drive shaft are slidable relative to the frame, wherein the body is rotationally secured to the drive shaft with a clip secured to the drive shaft and slidably coupled to the body, to transfer rotational input received from a first actuator to rotational movement of the drive shaft relative to the frame, wherein the rotational movement is transferred from the body through the clip to the drive shaft; and a drive link operably coupled to the frame and the body and configured to transfer a force received from a second actuator to a linear motion of the body that is transferred through the clip to the drive shaft, wherein the linear motion is transferred from the body indirectly through the biasing element to the clip and from the clip to the drive shaft to translate the drive shaft. forceps.

2. The forceps of claim 1 , wherein the clip is slidably coupled to the body along a track in the body.

3. the body includes an anchor portion having a distal spring seat; the clip providing a proximal spring seat; The biasing element is disposed between the distal spring seat and the proximal spring seat. The forceps according to claim 1.

4. The anchor portion further includes a rotational keying slot. The forceps according to claim 3.

5. The rotational keying slot extends parallel to the longitudinal axis of the drive shaft.

5. The forceps according to claim 4.

6. the body including a neck portion and a collar adapted for contact by the drive link; The forceps according to claim 1.

7. the drive link includes legs that fit around the neck portion and press against a drive surface of the collar; 7. The forceps according to claim 6.

8. a jaw coupled to a distal portion of the drive shaft; Rotational movement of the drive shaft rotates the jaws. The forceps according to claim 1.

9. a hub disposed about the body and at least a portion of the drive shaft; wherein rotational motion received from the first actuator is received by the hub, transferred from the hub to the body, transferred from the body to a clip, and transferred from the clip to the drive shaft. The forceps according to claim 1.

10. further comprising an outer shaft around the drive shaft; wherein the hub is rotationally fixed to the outer shaft; 10. The forceps according to claim 9.

11. The body includes a clip support surface; The biasing element drives the clip against the clip support surface under a preload. The forceps according to claim 1.

Images