Seals for surgical instruments

Abstract

The device includes a body, a shaft assembly, an end effector, a coupling member, and a sealing feature. The shaft assembly extends distally from the body and includes a distal end. The coupling member is disposed at the distal end of the shaft assembly for movably coupling the end effector to the shaft assembly. The sealing feature is engaged with the coupling member and includes a sealing body and a plurality of protrusions. The plurality of protrusions extend from the sealing body. Each protrusion of the plurality of protrusions is configured to slidably receive therethrough a respective elongate member associated with the end effector.

Description

[Background technology]

[0001] Various surgical instruments include end effectors for use in traditional medical procedures and techniques performed by medical professional operators, as well as applications in robotic-assisted surgery. Such surgical instruments may be directly grasped and manipulated by the surgeon or may be integrated into robotic-assisted surgery. In the case of robotic-assisted surgery, the surgeon may operate a master controller to remotely control the movement of such surgical instruments at the surgical site. The controller may be remotely located a significant distance from the patient (e.g., across the operating room, in a different room, or in a completely different building from the patient). Alternatively, the controller may be positioned very close to the patient in the operating room. In either case, the controller may include one or more hand input devices (such as a joystick, exoskeleton glove, master manipulator, etc.) coupled to the surgical instruments by servo mechanisms. In one example, servo motors move a manipulator supporting the surgical instruments based on the surgeon's manipulation of the hand input devices. During surgery, the surgeon may employ a variety of surgical instruments via the robotic surgical system, including ultrasonic blades, radio frequency tissue cutters and scissors, tissue graspers, needle holders, electrosurgical cauterization probes, etc. Each of these structures performs a function for the surgeon, such as cutting tissue, coagulating tissue, holding or driving a needle, grasping a blood vessel, cutting tissue, or cauterizing tissue.

[0002] In one example, the surgical instrument employed is operable to cut and / or seal tissue by applying radiofrequency (RF) electrosurgical energy to the tissue. Examples of such devices and related concepts are disclosed in U.S. Patent No. 7,354,440, entitled "Electrosurgical Instrument and Method of Use," issued April 8, 2008, the disclosure of which is incorporated herein by reference, and U.S. Patent No. 7,381,209, entitled "Electrosurgical Instrument," issued June 3, 2008, the disclosure of which is incorporated herein by reference.

[0003] While many different types of surgical instruments and related components have been made and used, it is believed that no one before the present inventors has made or used the invention set forth in the appended claims. [Brief explanation of the drawings]

[0004] The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate embodiments of the present invention and, together with the general description of the invention given above and the detailed description of the embodiments given below, serve to explain the principles of the invention. [Figure 1] 1 depicts a perspective view of an exemplary electrosurgical tool in combination with a generator, shown schematically; [Figure 2] 1 depicts a perspective view of a distal portion of another exemplary electrosurgical tool. [Figure 3] 3 depicts another perspective view of the distal portion of the tool of FIG. 2; [Figure 4] 3 depicts a side view of the intermediate portion of the tool of FIG. 2; [Figure 5] 3 depicts yet another perspective view of the distal portion of the tool of FIG. 2; [Figure 6] 3 depicts a perspective view of an exemplary proximal clevis that can be readily incorporated into the tool of FIG. 2, showing the proximal clevis coupled to a distal shaft portion of the tool of FIG. 2; [Figure 7] 7 depicts a perspective cross-sectional view of the proximal clevis and distal shaft portion of FIG. 6, the cross-section being taken along line 7-7 of FIG. 6. [Figure 8] 8 depicts another perspective cross-sectional view of the proximal clevis and distal shaft portion of FIG. 6, the cross-section being taken along line 8-8 of FIG. 6. [Figure 9] 7 depicts a perspective view of the sealing feature of the proximal clevis of FIG. 6; [Figure 10] 10 depicts another perspective view of the sealing feature of FIG. 9; [Figure 11A] 10 depicts a detailed perspective view of a portion of the sealing feature of FIG. 9 with a web in place during the overmolding process. [Figure 11B] 11B depicts another detailed perspective view of a portion of the sealing feature of FIG. 9 with the web of FIG. 11A removed. [Figure 12] 11B depicts a schematic diagram of an exemplary mold for use with the overmolding process of FIG. 11A. [Figure 13] 7 depicts yet another cross-sectional perspective view of the proximal clevis and distal shaft portion of FIG. 6 with the cables and wires of the tool of FIG. 2 extending therethrough; [Figure 14] 13 depicts yet another perspective cross-sectional view of the proximal clevis and distal shaft portion of FIG. 6 with the cables and wires of FIG. 12 extending therethrough; [Figure 15] 13 depicts an enlarged cross-sectional side view of the proximal clevis and distal shaft portion of FIG. 6 with the cables and wires of FIG. 12 extending therethrough. [Figure 16] 3 depicts a perspective view of another exemplary proximal clevis that can be readily incorporated into the tool of FIG. 2, showing the proximal clevis coupled to the distal shaft portion of the tool of FIG. 2; [Figure 17] 17 depicts a perspective cross-sectional view of the proximal clevis and distal shaft portion of FIG. 16, the cross-section being taken along line 17-17 of FIG. 16. [Figure 18] 17 depicts a perspective view of the sealing feature of the proximal clevis of FIG. 16; [Figure 19] 19 depicts another perspective view of the sealing feature of FIG. 18; [Figure 20] 17 depicts another perspective cross-sectional view of the proximal clevis and distal shaft portion of FIG. 16 with the cable of the tool of FIG. 2 extending therethrough;

[0005] The drawings are not intended to be limiting in any manner, and it is contemplated that various embodiments of the invention may be embodied in a variety of other ways, including those not necessarily depicted in the drawings. The accompanying drawings, which are incorporated in and constitute a part of this specification, illustrate several aspects of the invention and, together with the description, serve to explain the principles of the invention, it being understood, however, that the invention is not limited to the precise configurations shown. DETAILED DESCRIPTION OF THE INVENTION

[0006] The following description of specific examples of the present technology should not be used for the purpose of limiting its scope. Other examples, features, aspects, embodiments, and advantages of the present technology will become apparent to those skilled in the art from the following description, which is illustrative and illustrates one of the best modes contemplated for carrying out the present technology. As will be understood, the technology described herein is capable of other different and obvious aspects, all without departing from the technology. Therefore, the drawings and descriptions should be regarded as illustrative in nature, and not restrictive.

[0007] It will be further understood that any one or more of the teachings, expressions, embodiments, examples, etc. described herein can be combined with any one or more of the other teachings, expressions, embodiments, examples, etc. described herein. Therefore, the teachings, expressions, embodiments, examples, etc. described below should not be considered in isolation from one another. Various suitable ways in which the teachings herein can be combined will be readily apparent to those of ordinary skill in the art in light of the teachings herein. Such modifications and variations are intended to be within the scope of the claims.

[0008] For clarity of this disclosure, the terms "proximal" and "distal" are defined herein relative to a human or robotic surgical instrument operator. The term "proximal" refers to the location of an element closer to a human or robotic surgical instrument operator and further from a surgical end effector of the surgical instrument. The term "distal" refers to the location of an element closer to a surgical end effector of the surgical instrument and further from a human or robotic surgical instrument operator. Additionally, the terms "upper," "lower," "lateral," "transverse," "bottom," and "top" are relative terms to provide further clarity in the description of the figures provided below. The terms "upper," "lower," "lateral," "transverse," "bottom," and "top," therefore, are not intended to unnecessarily limit the invention(s) described herein.

[0009] I. Exemplary Electrosurgical Tools FIG. 1 illustrates an exemplary electrosurgical tool (100). The term "tool" is used herein in reference to the electrosurgical tool (100), although it should be understood that in other contexts, the term "instrument" may alternatively be used. The tool (100) includes an elongate shaft (102), an end effector (104) coupled to the distal end of the shaft (102), and a proximal housing portion (106) including a housing (110) coupled to the proximal end of the shaft (102). The end effector (104) of this example includes first and second jaw members (108a, 108b), also referred to herein as "jaws," and is configured to move between an open configuration and a closed configuration. The end effector 104 is shown in FIG. 1 in the open configuration. The first and second jaw members (108a, 108b) have a generally straight configuration, although in other embodiments, one or both of the first and second jaw members (108a, 108b) may have a curved configuration. The jaw members (108a, 108b) are configured to capture or engage tissue by closing to clamp or grasp the tissue therebetween. As such, it should be understood that the first and second jaw members (108a, 108b) are generally configured to apply compression to the clamped tissue.

[0010] One or both of the jaw members (108a, 108b) may include an electrode for providing electrosurgical energy to tissue. By way of example only, the first and second jaw members (108a, 108b) may each include at least one electrode, e.g., the tool (100) may be bipolar, such that electrical current can flow between electrodes in the opposing jaw members (108a, 108b) and through tissue positioned therebetween. In this example, the first jaw member (108a) has an electrode (112a) on its tissue-facing surface, and the second jaw member (108b) has an electrode (112b) on its tissue-facing surface. While the jaw members (108a, 108b) in this example are configured in a bipolar electrode configuration, it should be understood that in other examples, the jaw members (108a, 108b) may be configured in a monopolar configuration in which only one of the jaw members (108a, 108b) includes an electrode (112a, 112b). Each of the electrodes (112a, 112b) is generally configured to be positioned relative to tissue so that an electric current can flow through the tissue. The electric current can generate heat within the tissue, which in turn forms one or more hemostatic seals within and / or between the tissues. For example, tissue heating caused by the electric current can at least partially denature proteins within the tissue. Such proteins, such as collagen, can be denatured into a proteinaceous amalgam that mixes and fuses together, or "coagulates," or "fuses," as the proteins unfold. As the treatment area heals over time, this biological "weld" can be reabsorbed by the body's wound healing process. As explained above, the applied energy can include high frequency alternating current, such as RF energy. When applied to tissue, RF energy can cause ionic agitation or friction, increasing the temperature of the tissue.Various embodiments for applying RF energy are further described in U.S. Pat. No. 10,441,345, entitled "Surgical Generator For Ultrasonic And Electrosurgical Devices," issued on October 15, 2019; U.S. Pat. No. 9,161,803, entitled "Motor Driven Electrosurgical Device With Mechanical And Electrical Feedback," issued on October 20, 2015; and U.S. Pat. No. 9,802,033, entitled "Surgical Devices Having Controlled Tissue Cutting And Sealing," issued on October 31, 2017, each of which is incorporated herein by reference in its entirety.

[0011] Although not shown, it should be understood that in some embodiments, the tool (100) can include a cutting element (not shown), which can be configured as an I-beam or other suitable structural knife. A suitable cutting element can be configured to translate along the axial length of the end effector (104), thereby cutting or traversing tissue positioned between the jaw members (108 a, 108 b). Such cutting can occur during or after the application of electrosurgical energy.

[0012] The tool (100) is configured to be operatively coupled to a generator (118). In this embodiment, the tool (100) is connected to the generator (118) using a cable (120), but may be connected in other ways, as will be understood by those skilled in the art. The generator (118) is configured as an energy source, such as an RF source, an ultrasound source, a DC source, or the like, to deliver energy to the tool (100) to enable the electrodes (112a, 112b) to apply energy to tissue. In this embodiment, the generator (118) may be coupled to a controller, such as a control unit. The control unit may be integrally formed with the generator (118) or may be provided as a separate, independent device electrically coupled to the generator (118) (shown in phantom in FIG. 1 to illustrate this option). A suitable control unit may be configured to regulate the energy delivered by the generator (118), which in turn delivers energy to the electrodes (112a, 112b). Energy delivery may be initiated in any suitable manner. By way of example only, the tool 100 may be energized by a generator 118 via activation of a footswitch. When activated, the footswitch (or other activated actuator) triggers the generator 118 to deliver energy to the end effector 104. The control unit may be configured to regulate the power generated by the generator 118, for example, as discussed further below. Also, as discussed further below, the control unit, as a separate and independent device from the generator 118, may be part of a robotic surgical system.

[0013] For example, proximal housing portion (106) within housing (110) includes a drive system (not shown) configured to operably couple to at least one motor for driving the drive system to cause the execution of various functions of tool (100), such as closing jaw members (108 a, 108 b), opening jaw members (108 a, 108 b), articulating end effector (104) relative to shaft (102), rotating shaft (102) about its longitudinal axis, moving a cutting element (not shown) along end effector (104), and applying energy. By way of example only, tool (100) may include a drive system having one or more separate drive systems configured to drive various components of tool (100). For example, the drive systems may include separate or combined drive assemblies configured to drive rotation of the shaft 102, drive rotation of an end deflector, drive articulation of the end effector 104 in first and second opposing directions (FD, SD), drive articulation of the end effector 104 in third and fourth opposing directions (TD, FTHD), drive a closure assembly to selectively open or close the end effector 104, etc. While specific details are not shown, it should be understood that each drive system may include one or more mechanical or electromechanical components operable to drive the various movements of the shaft 102 and / or end effector 104 described above. Additionally, one or more of each drive system may be in communication with another drive system, for example, to drive multiple movements using a single rotational input. By way of example only, suitable mechanical or electromechanical components may include gears, cables, springs, belts, lead screws, splines, linear actuators, cylinders, pistons, racks, pinions, and the like.In some embodiments, each drive system can be configured in accordance with at least some of the teachings of U.S. Patent Publication No. 2019 / 0059987, filed August 29, 2017, entitled "Methods, Systems, and Devices for Controlling Electrosurgical Tools," the disclosure of which is incorporated herein by reference in its entirety.

[0014] 2-5 illustrate an exemplary alternative electrosurgical tool (300) substantially similar to the tool (100) described above, unless otherwise noted. For example, the tool (300) of this example is generally configured and used similarly to the tool (100) of FIG. 1 and similarly includes an elongate shaft (302), an end effector (304) coupled to the distal end of the shaft (302) and including first and second jaw members (306 a, 306 b), and a proximal housing portion (not shown) including a drive system (not shown) coupled to the proximal end of the shaft (302). One or both jaw members (306 a, 306 b) may include electrodes operable to deliver RF energy to tissue. Similar to the proximal housing portion (106) of FIG. 1 discussed above, the proximal housing portion of the tool (300) may be configured to operably couple to a tool driver of a robotic surgical system, or the proximal housing portion may be configured to be handheld and manually operated.

[0015] Tool (300) includes a plurality of elongated actuatable drive members, shown in the form of cables (308, 310, 312, 314), which are configured to be actuated to selectively cause the opening of end effector (304), the closing of end effector (304), and the articulation of end effector (304) relative to shaft (302). Cables (308, 310, 312, 314) are attached to end effector (304) and extend along solid surfaces of guide channels in end effector (304), distal clevis (316), and proximal clevis (318), from which they extend proximally through shaft (302) to the proximal housing portion.

[0016] In addition to the cables (308, 310, 312, 314), the tool (300) may also include one or more elongated conductive members, shown in the form of wires (319), that extend through the shaft (302) to the end effector (304) or other portions of the tool (300). For example, as best seen in FIG. 3 , one or more wires (319) may extend through the shaft (302), the proximal clevis (318), and the distal clevis (316) to the end effector (304). Such one or more wires (319) may be used for various conductive purposes. For example, as described above, the tool (300) is configured to operably connect to a generator substantially similar to generator (118) to generate energy that can be used in connection with the end effector (304). By way of example only, in some configurations, the end effector 304 may be equipped with electrodes similar to the electrodes 112 a, 112 b described above. In such embodiments, one or more wires 319 may be used to deliver RF energy from the generator to the electrodes. Of course, in other embodiments, various alternative uses for the one or more wires 319 may be used, as would be apparent to one of ordinary skill in the art in view of the teachings herein.

[0017] As best seen in FIG. 5 , the distal clevis (316) is configured to rotate (322) relative to the proximal clevis (318) about a pin (324) that defines a pitch axis. Rotation of the distal clevis (316) relative to the proximal clevis (318) is driven about the pitch axis in response to cable actuation. In particular, for clockwise rotation about the pitch axis, the drive system, in response to control thereof (e.g., in response to motor force delivered thereto), retracts equal lengths of third and fourth cables (312, 314) while releasing equal lengths of the first and second cables (308, 310). The third and fourth cables (312, 314) exert a force on the distal clevis (316) at a moment arm defined by the guide channels of the third and fourth cables (312, 314) through the distal clevis (316). Similarly, for counterclockwise rotation of the distal clevis (316) about the pitch axis, the drive system responds to the control by retracting first and second cables (308, 310) of equal length while releasing third and fourth cables (312, 314) of equal length.

[0018] The proximal clevis (318) is fastened to the distal end of the shaft (302) and extends distally therefrom. The proximal clevis (318) is generally configured to receive a portion of the distal clevis (316) and allow rotation (322) of the distal clevis (316) relative to the shaft (302). In other words, the proximal clevis (318) provides a connection point between the distal clevis (316) and the shaft (302) to facilitate movement of the distal clevis (316) relative to the shaft (302). As noted above, the distal clevis (316) is fastened to the proximal clevis (318) by a pin (324) that defines a pitch axis. Additionally, as best seen in FIG. 6, the proximal clevis (318) is generally hollow so that cables (308, 310, 312, 314) and / or one or more wires (319) may extend through the proximal clevis (318) to the distal clevis (316) and / or the end effector (304).

[0019] A pin (320) in the distal clevis (316) is perpendicular to the pin (324) and defines a pivot or yaw axis about which the end effector (304) is configured to rotate (326) relative to the distal clevis (316) and about which the jaw members (306a, 306b) are configured to rotate (328) independently to open and close in response to cable actuation. Specifically, first and second cables (308, 310) are attached to the first jaw member (306a), and third and fourth cables (312, 314) are attached to the second jaw member (306b). The attachment of the first and second cables (308, 310) to the first jaw member (306a) is such that a length of one cable (308 or 310) is retracted and an equal length of the other cable (308 or 310) is released, causing rotation of the first jaw member (306a) about the pin (320). Similarly, the attachment of the third and fourth cables (312, 314) to the second jaw member (306b) is such that a length of one cable (312 or 314) is retracted and an equal length of the other cable (312 or 314) is released, causing rotation of the second jaw member (306b) about the pin (320). Thus, the closure assembly of the tool (300) includes the cables (308, 310, 312, 314).

[0020] The cables (308, 310, 312, 314) may be driven by one or more drive systems configured to selectively retract the cables (308, 310, 312, 314) in a proximal direction. It will be understood that such drive systems and other features and functions of the surgical tool (300) may be configured in accordance with at least some of the teachings of U.S. Patent Publication No. 2019 / 0059987, which was incorporated by reference above. Exemplary embodiments of electrosurgical tools are further described in U.S. Patent No. 9,119,657, entitled "Rotary Actuatable Closure Arrangement For Surgical End Effector," filed June 28, 2012, and U.S. Patent No. 8,771,270, entitled "Bipolar Cautery Instrument," filed July 16, 2008, which are incorporated by reference herein in their entireties.

[0021] II. Exemplary Alternative Clevises with Sealing Features In some cases, it may be desirable to equip portions of the electrosurgical tool (100, 300) with sealing components. Such sealing components may be desirable to prevent fluid ingress into the tool (100, 300) and to maintain insufflation of the patient's body cavity during a laparoscopic surgical procedure. Fluid ingress is generally undesirable in both robotic and handheld applications of the instrument. For example, fluid ingress into certain shaft portions of a surgical instrument may be particularly difficult to effectively clean and / or sterilize during a surgical procedure. Furthermore, fluid ingress may indicate an inefficiently sealed structure, thus prone to leakage of insufflation gas from the insufflated body cavity, which may reduce the efficiency of the surgical procedure.

[0022] Accordingly, it is generally desirable to incorporate robust sealing components into various portions of electrosurgical tool (100, 300). Various examples of sealing components are described in more detail below. However, it should be understood that a variety of alternative configurations may be used without departing from the nature of the subject matter described herein. Additionally, while the sealing components described herein are described in connection with electrosurgical tools (100, 300), it should be understood that such sealing components may readily be incorporated into a variety of alternative surgical tools other than those described herein, such as surgical tools configured to grasp, cut, and / or staple tissue, which may or may not be configured to apply RF energy to tissue.

[0023] 6 depicts an exemplary alternative proximal clevis (418) substantially similar to the proximal clevis (318) described above. As will be appreciated, the proximal clevis (418) can be readily incorporated into the electrosurgical instrument (300) or other suitable surgical tool or instrument in place of the proximal clevis (318) described above. While the term "proximal clevis" is used herein to refer to the proximal clevis (418), in some contexts the terms "coupling member," "coupler," or simply "clevis" may be used to refer to the proximal clevis (418). Similar to the proximal clevis (318) discussed above, the proximal clevis (418) of this example is configured to fasten to the distal end of the shaft (302) and extend distally therefrom. Similarly, the proximal clevis (418) is generally configured to receive a portion of the distal clevis (316) to allow rotation of the distal clevis (316) relative to the shaft (302). In other words, the proximal clevis (418) provides a connection point between the distal clevis (316) and the shaft (302) to facilitate movement of the distal clevis (316) relative to the shaft (302). As also noted above, the distal clevis (316) can be fastened to the proximal clevis (418) by a pin (324) that defines a pitch axis for rotation of the distal clevis (316). Additionally, the proximal clevis 418 is generally hollow so that the cables 308, 310, 312, 314 and / or one or more wires 319 may extend through the proximal clevis 418 to the distal clevis 316 and / or the end effector 304. To support the functions discussed above, the proximal clevis 418 may include certain structural features, such as an annular base having an irregularly shaped central opening. In some embodiments, the proximal clevis 418 may further include a pair of arms extending distally from the annular base to support the pin 324 and the distal clevis 316, as described above.

[0024] As best seen in FIGS. 7 and 8 , unlike the proximal clevis 318 discussed above, the proximal clevis 418 of this embodiment includes a sealing feature 430 disposed within an interior portion of the clevis 418. The sealing feature 430 is generally configured to provide a robust, fluid-tight seal at the distal end of the shaft 302 to prevent fluid ingress (e.g., liquid and gas ingress) from outside the shaft 302 into the shaft 302. Meanwhile, the sealing feature 430 is also generally configured to allow various components, such as cables and / or wires, to easily communicate with the end effector 304 while maintaining the robust fluid seal described above. As discussed in more detail below, such communication with the end effector 304 through the sealing feature 430 may involve movement of various components relative to the sealing feature 430. Thus, sealing feature 430 includes specific features that facilitate movement of components relative thereto while also maintaining a fluid-tight seal. While sealing feature 430 is discussed herein in connection with clevis 418, it should be understood that in other examples, sealing feature 430 may readily be incorporated into other components of tool 300 or into other tools or instruments overall.

[0025] The sealing feature 430 in this example is generally formed from a single piece of compliant material that is overmolded into the clevis 418. Using a compliant material for the sealing feature 430 is generally desirable to promote reduced wear. Using a compliant material for the sealing feature 430 is further desirable to accommodate flexing of the sealing feature 430 while maintaining an adequate seal with the elongated components extending therethrough. In some embodiments, a suitable compliant material may include silicone or other similar materials. While the sealing feature 430 is described herein as being overmolded into the proximal clevis 418, it should be understood that in some embodiments, the sealing feature 430 may alternatively be molded separately and then attached to the proximal clevis 418 by adhesive bonding, welding, and / or mechanical fastening.

[0026] 7-10 , the sealing feature 430 includes a sealing body 432 and a plurality of protrusions 440, 450, referred to herein as dimples, extending axially relative to the sealing body 430. The sealing body 432 generally extends laterally across the hollow interior defined by the proximal clevis 418 to seal the interior of the shaft 302 from the exterior of the shaft 302. As described in more detail below, aside from the dimples 440, 450, the sealing body 432 is generally continuous across the hollow interior of the proximal clevis 418 and prevents fluid flow therethrough.

[0027] The seal body 432 is generally configured to fit within the internal structure of the proximal clevis 418. In this embodiment, the seal body 432 has a generally irregular shape that may be characterized in some respects as a multi-piece structure with a distal seal portion 434, a proximal seal portion 436, and a gap 438 positioned therebetween. In some embodiments, such structure of the seal body 432 may be formed by at least a portion of the proximal clevis 418 to provide additional structural rigidity to the seal body 432. For example, the gap 438 may be formed by one or more internal structures of the proximal clevis 418 extending through a hollow interior of the proximal clevis 418. During the overmolding process, such one or more internal structures may be surrounded by the material forming the seal body 432.

[0028] While a particular configuration of the seal body 432 is shown in this example, it should be understood that the seal body 432 may take a variety of forms depending on the internal configuration of the proximal clevis 418. The preferred form of the seal body 432 and / or the proximal clevis 418 may be configured according to various considerations, such as the desired stiffness of the seal body 432, ease of manufacture, and the desired contact surface area between the seal body 432 and the proximal clevis 418.

[0029] As discussed above, the sealing feature (430) is configured to seal the interior of the proximal clevis (418) while still allowing communication between various components and the end effector (304). Accordingly, the sealing feature (430) is configured to receive one or more components of the tool (300) so that such components may pass through the sealing feature (430) to the end effector (304). To facilitate such functionality, the sealing feature (430) includes dimples (440, 450) positioned to receive one or more components of the tool (300), as described in more detail below.

[0030] As can be seen, each dimple (440, 450) extends proximally from the distal sealing portion (434) within the seal body (432) and from the proximal sealing portion (436) of the seal body (432). Thus, each dimple (440, 450) defines a generally conical protrusion through which a particular portion of the tool (300) may extend. While each dimple (440, 450) is shown as proximally protruding in this example, it should be understood that in other examples, one or more of the dimples (440, 450) may alternatively protrude distally rather than proximally. In such configurations, the various structures of the dimples (440, 450) described herein are generally inverted, either proximally to distally or distally to proximal.

[0031] Each dimple (440, 450) includes a tapered receiving portion (442, 452) and a sealing portion (446, 456). The receiving portion (442, 452) of each dimple (440, 450) is defined by the seal body (432) as a hole extending therethrough. The receiving portion (442, 452) of each dimple (440, 450) is generally cylindrical and tapered in shape, similar to a countersink. By way of example only, in some cases, the taper angle of each receiving portion (442, 452) may be approximately 8 degrees.

[0032] A sealing portion (446, 456) of each dimple (440, 450) projects proximally from a corresponding receiving portion (442, 452). In addition, each sealing portion (446, 456) projects proximally from a proximal face of seal body (432). As described in more detail below, each sealing portion (446, 456) can be configured to bend or flex in response to movement of one or more components of tool (300) to maintain a fluid-tight seal.

[0033] The sealing portion (446, 456) of each dimple (440, 450) includes a sealing aperture (448, 458) extending longitudinally through the entire sealing portion (446, 456). Each sealing aperture (448, 458) communicates with a corresponding receiving portion (442, 452) to define a continuous longitudinal path through the entire sealing feature (430). As described in more detail below, this continuous longitudinal path generally allows various elongated components of the tool (300) to pass through the sealing feature (430).

[0034] Each sealing hole (448, 458) in this example defines a generally cylindrical shape. The particular diameter of each sealing hole (448, 458) generally corresponds to the diameter of a particular component of tool (300), as described in more detail below. Regardless of the particular component received within each sealing hole (448, 458), it should be understood that the diameter of each sealing hole (448, 458) is configured to provide a sealing fit with the particular component received therein. In some embodiments, this sealing fit may be characterized as a compression or interference fit. Additionally, such a sealing fit may still be configured to provide at least some translational movement of the corresponding component of tool (300) relative to each sealing portion (446, 456).

[0035] 11A-12 illustrate an exemplary process for forming each seal hole (448, 458) during the overmolding process described above. In some overmolding processes, the first mold portion (472) of the mold (470) may include a core pin (474), and a pin or other structure may be used to form a through-hole similar to each seal hole (448, 458). However, in some variations of this embodiment, scales on each seal hole (448, 458) may lead to the core pin (474) or other similar structure contacting the opposing surface of the second mold portion (476) of the mold (470) used in the overmolding process. This is generally an undesirable condition, as it may result in damage to the core pin (474) or other parts of the mold (470). Therefore, in some overmolding processes, it may be desirable to include steps or features to avoid contact between at least the free end of the core pin (474) and other parts of the mold (470).

[0036] In this exemplary process, each core pin (474) of the mold (470) is shortened so that only a portion of each seal hole (448, 458) is formed by the respective core pin (474) itself. This allows the proximal end portion of each seal hole (448, 458) to be covered or filled with a thin layer of excess material or web (460), which is integrally formed with the proximal end of each dimple (440, 450) and is therefore disposed in opposing, face-to-face relation with the free end of each core pin (474) during the overmolding process. Each web (460) can later be removed after the molding process is completed to form the proximal end opening of each seal hole (448, 458).

[0037] Once the molding process is complete, each web (460) can be removed from its respective dimple (440, 450) using a variety of processes. For example, in one exemplary process, screws, hooks, or other gripping features (482) can be integrated into the second mold section (476) of the mold (470), or a similar section thereof that faces the particular mold section containing the core pin (474), at locations where the free end of each gripping feature projects toward and aligns with each opposing formed dimple (440, 450) of the corresponding core pin (474). Such screws, hooks, or gripping features can engage the web (460) during molding, for example, by being partially embedded within the web (460), and then tear the web (460) along with any other excess material away from each formed dimple (440, 450) when the mold sections (472, 476) are separated from one another after molding is complete. To facilitate such tearing of each web (460) without unintentionally deforming the sealing portions (446, 456) of the corresponding formed dimples (440, 450), the webs (460) may be formed with an axial thickness less than the wall thickness of the radial sealing portions (446, 456). In other embodiments, the webs (460) and any excess material may be removed from the proximal end portions of each formed dimple (440, 450) by piercing them with a sharp object. Alternatively, in yet other embodiments, the webs (460) and any excess material may be removed using a laser cutting process. Still other alternative processes for removing the webs (460) and any excess material will be apparent to those skilled in the art in view of the teachings herein.

[0038] The dimples (440, 450) of this example can be configured to receive different sized components of the tool (300). For example, as best seen in FIGS. 13 and 14 , the sealing feature (430) of this example includes four cable dimples (440) configured to receive the cables (308, 310, 312, 314) described above, respectively. Accordingly, the sealing hole (448) of each cable dimple (440) has a diameter corresponding to the outer diameter of the corresponding cable (308, 310, 312, 314) such that the sealing portion (446) of each cable dimple (440) is configured to sealingly engage the corresponding cable (308, 310, 312, 314). Similarly, a particular number of cable dimples (440) corresponds to a particular number of cables (308, 310, 312, 314). Thus, in embodiments in which tool (300) includes more or fewer cables (308, 310, 312, 314), sealing feature (430) may include more or fewer cable dimples (440) as well.

[0039] The sealing feature 430 of this example also includes two wire dimples 450 configured to receive a respective wire 319, as described above. Accordingly, the sealing hole 458 of each wire dimple 450 has a diameter corresponding to the outer diameter of the corresponding wire 319, such that the sealing portion 456 of each wire dimple 450 is configured to sealingly engage the corresponding wire 319. Similarly, the specific number of each wire dimple 450 corresponds to the specific number of wires 319. Accordingly, in examples in which the tool 300 includes more or fewer wires 319, the sealing feature 430 may similarly include more or fewer wire dimples 450.

[0040] Although dimples 440, 450 are described herein in the context of receiving either cables 308, 310, 312, 314 or wires 319, it should be understood that in other embodiments, dimples 440, 450 may be configured to readily receive other components of surgical tool 300. For example, in some embodiments, tool 300 may include tubes, cannulas, etc. for providing various fluids to end effector 304. In such embodiments, sealing feature 430 may similarly include structure similar to dimples 440, 450 for receiving such tubes, cannulas, etc.

[0041] As best seen in FIG. 15 , each cable dimple (440) is configured to receive a corresponding cable (308, 310, 312, 314) such that the corresponding cable (308, 310, 312, 314) can freely slide and / or translate longitudinally through and relative to the sealing feature (430). Additionally, each cable dimple (440) is configured to flex laterally relative to the longitudinal axis of the shaft (302) to accommodate lateral movement of the cables (308, 310, 312, 314). Such lateral flexion may be desirable to accommodate articulation of the end effector (304). For example, during use, articulation of the end effector (304) may result in some deflection of the cables (308, 310, 312, 314) during the articulation process. While each cable dimple (440) flexes in response to such deflection of the cables (308, 310, 312, 314), each cable dimple (440) is configured to maintain sealing engagement with each corresponding cable (308, 310, 312, 314) despite such deflection. Although not shown in FIG. 15 , it should be understood that wire dimples (450) may similarly support such deflection of the wires (319) during articulation of the end effector (304).

[0042] 15 depicts another exemplary alternative proximal clevis (518) that is substantially similar to the proximal clevis (318) described above. As can be appreciated, the proximal clevis (518) can be readily incorporated into the electrosurgical instrument (300) or other suitable surgical tool or instrument in place of the proximal clevis (318) described above. Similar to the proximal clevis (318) discussed above, the proximal clevis (518) of this example is configured to fasten to the distal end of the shaft (302) and extend distally therefrom. Similarly, the proximal clevis (518) is generally configured to receive a portion of the distal clevis (316) and allow rotation of the distal clevis (316) relative to the shaft (302). In other words, the proximal clevis 518 provides a connection point between the distal clevis 316 and the shaft 302 to facilitate movement of the distal clevis 316 relative to the shaft 302. As also noted above, the distal clevis 316 may be fastened to the proximal clevis 518 by a pin 324, which defines a pitch axis for rotation of the distal clevis 316. Additionally, the proximal clevis 518 is generally hollow so that the cables 308, 310, 312, 314 and / or one or more wires 319 may extend through the proximal clevis 518 to the distal clevis 316 and / or the end effector 304.

[0043] As best seen in FIG. 17 , unlike the proximal clevis 318 discussed above, the proximal clevis 518 of this embodiment includes a sealing feature 530 disposed within an interior portion of the clevis 518. The sealing feature 530 is generally configured to provide a robust, fluid-tight seal at the distal end of the shaft 302 to prevent ingress of fluid into the shaft 302 from outside the shaft 302. Meanwhile, the sealing feature 530 is also generally configured to allow various components, such as the cables 308, 310, 312, 314 and / or wires 319, to easily communicate with the end effector 304 while maintaining the robust fluid seal described above. As discussed in more detail below, such communication with the end effector 304 through the sealing feature 530 may involve movement of the various components relative to the sealing feature 530. Thus, sealing feature 530 includes specific components for facilitating movement of components relative thereto while also maintaining a fluid-tight seal. While sealing feature 530 is discussed herein in connection with clevis 518, it should be understood that in other examples, sealing feature 530 may readily be incorporated into other components of tool 300 or into other tools or instruments as a whole.

[0044] The sealing feature 530 of this example is generally substantially similar to the sealing feature 430 described above. For example, like sealing feature 430, the sealing feature of this example is formed from a single, compatible material that is overmolded or otherwise fastened to the interior of the proximal clevis 518. The sealing feature 530 also includes a sealing body 532, similar to sealing body 432, that defines a plurality of dimples 540. As also discussed above, the sealing body 532 generally extends laterally across the hollow interior defined by the proximal clevis 518 to seal the interior of the shaft 302 from the exterior of the shaft 302.

[0045] Similar to the seal body 432 described above, the seal body 532 of this example has a generally irregular shape defining a distal seal portion 534, a proximal seal portion 536, and a gap 538 positioned therebetween. In some embodiments, such structure of the seal body 532 may be formed by at least a portion of the proximal clevis 518 to provide additional structural rigidity to the seal body 532. For example, the gap 538 may be formed by an internal structure of the proximal clevis 518 extending through a hollow interior of the proximal clevis 518. During the overmolding process, one or more such internal structures may be surrounded by the material forming the seal body 532.

[0046] Also, similar to sealing feature 430 described above, sealing feature 530 in this example includes dimples 540 positioned to receive one or more components of tool 300. As also discussed above, each dimple 540 extends proximally from distal sealing portion 534 within sealing body 532 and proximally from proximal sealing portion 536 of sealing body 532. Thus, each dimple 540 defines a generally conical protrusion through which a particular portion of tool 300 may extend. While each dimple 540 is shown as proximally protruding in this example, it should be understood that in other examples, one or more of dimples 540 may alternatively protrude distally rather than proximally. In such a configuration, the various structures of the dimples (540) described herein are generally inverted from proximal to distal or distal to proximal.

[0047] Similar to dimples 440 described above, each dimple 540 includes a tapered receiving portion 542 and a sealing portion 546. The receiving portion 542 of each dimple 540 is defined by seal body 532 as a tapered bore extending therethrough, while the sealing portion 546 of each dimple 540 protrudes proximally from the corresponding receiving portion 542 and also protrudes proximally from the proximal surface of seal body 532. The sealing portion 546 of each dimple 540 also includes a sealing hole 548, similar to sealing hole 448, extending longitudinally through the entire sealing portion 546. Similar to the sealing holes (448) described above, each sealing hole (548) in this embodiment defines a generally cylindrical shape that generally corresponds to the diameter of a particular component of tool (300) therein to provide a sealing fit with such component of tool (300).

[0048] The dimples (540) of this example can be configured to receive different sized components of the tool (300). For example, as best seen in FIG. 20 , the sealing feature (530) of this example includes four cable dimples (540) configured to receive the cables (308, 310, 312, 314) described above. Accordingly, the sealing hole (548) of each cable dimple (540) has a diameter corresponding to the outer diameter of the corresponding cable (308, 310, 312, 314) such that the sealing portion (546) of each cable dimple (540) is configured to sealingly engage the corresponding cable (308, 310, 312, 314). Similarly, a specific number of each cable dimple (540) corresponds to a specific number of cables (308, 310, 312, 314). Thus, in embodiments in which tool (300) includes more or fewer cables (308, 310, 312, 314), sealing feature (530) may include more or fewer cable dimples (540) as well.

[0049] Unlike the sealing feature 430 described above, the sealing feature 530 of this embodiment omits structures similar to wire dimples 450. Thus, the sealing feature 540 of this embodiment is configured for use with tool 300 variations that do not have one or more wires 319, or in which wires 319 are present but do not extend to the end effector 304.

[0050] Although dimples 540 are described herein in the context of receiving cables 308, 310, 312, 314, it should be understood that in other embodiments, dimples 540 may be configured to readily receive other components. For example, in some embodiments, tool 300 may include tubes, cannulas, etc. for providing various fluids to end effector 304. In such examples, sealing feature 530 may similarly include structure similar to dimples 540 for receiving such tubes, cannulas, etc.

[0051] As best seen in FIG. 20 , each cable dimple (540) is configured to receive a corresponding cable (308, 310, 312, 314) such that the corresponding cable (308, 310, 312, 314) can freely slide and / or translate longitudinally relative to the sealing feature (530). Additionally, each cable dimple (540) is configured to flex laterally to accommodate lateral movement of the cable (308, 310, 312, 314). Such lateral flexing may be desirable to accommodate articulation of the end effector (304). For example, during use, articulation of the end effector (304) may result in some deflection of the cables (308, 310, 312, 314) during the articulation process. While each cable dimple (540) bends in response to such deflection of the cables (308, 310, 312, 314), each cable dimple (540) is configured to maintain sealing engagement with each corresponding cable (308, 310, 312, 314) despite such deflection.

[0052] III. Exemplary Combinations The following examples relate to various non-exhaustive ways in which the teachings herein can be combined or applied. It should be understood that the following examples are not intended to limit the scope of any claims that may be presented at any time in this application or any subsequent application related to this application. No disclaimer is intended. The following examples are provided merely for illustrative purposes. It is contemplated that the various teachings herein may be configured and applied in many other ways. It is also contemplated that certain features referred to in the following examples may be omitted in some variations. Accordingly, none of the aspects or features referred to below should be considered critical unless later expressly indicated as such by the inventors or their successors. If a claim presented in this application or a subsequent application related to this application includes additional features other than those referred to below, those additional features should not be considered added for any reasons of patentability. [Example]

[0053] 1. An apparatus comprising: a body; a shaft assembly extending distally from the body, the shaft assembly including a distal end; an end effector; a coupling member disposed at the distal end of the shaft assembly for movably coupling the end effector to the shaft assembly; and a sealing feature engaged with the coupling member, the sealing feature including a seal body and a plurality of protrusions extending from the seal body, each protrusion of the plurality of protrusions configured to slidably receive a respective elongated member associated with the end effector therethrough. [Example]

[0054] 2. The device of example 1, wherein each protrusion defines a receiving portion and a sealing portion, the sealing portion configured to sealingly engage the elongate member. [Example]

[0055] The device of example 2, wherein the sealing portion is configured to flex upon lateral movement of the elongated member relative to the longitudinal axis of the shaft assembly. [Example]

[0056] The device of example 2, wherein the sealing portion is configured to flex in response to lateral movement of the elongated member relative to the longitudinal axis of the shaft assembly while maintaining sealing engagement with the elongated member. [Example]

[0057] The device of any one or more of Examples 1-4, wherein the sealing portion defines a sealing hole, the sealing hole defining a diameter approximately equal to a diameter of the elongate member. [Example]

[0058] The device of any one or more of Examples 1-5, wherein the receiving portion defines a tapered bore extending therethrough and in communication with at least a portion of the sealing portion. [Example]

[0059] The device of Example 1, further comprising a plurality of cables extending from the body through the shaft assembly to the end effector, each cable being movable relative to the body to drive movement of the end effector, and each protrusion of the plurality of protrusions configured to slidably receive a corresponding cable to enable movement of the end effector via one or more cables of the plurality of cables. [Example]

[0060] 8. The device of example 7, wherein each protrusion is configured to bend laterally in response to lateral deflection of a corresponding cable via movement of the end effector. [Example]

[0061] The device of Example 1, further comprising a plurality of cables configured to drive the end effector and one or more wires configured to transmit RF energy to the end effector, wherein the plurality of cables and the one or more wires extend from the body through the shaft assembly to the end effector, one or more protrusions of the plurality of protrusions configured to slidably receive one of the plurality of cables, and one or more protrusions of the plurality of protrusions configured to slidably receive one of the one or more wires. [Example]

[0062] 10. The device of example 9, wherein each protrusion of the plurality of protrusions is configured to bend in response to lateral movement of the respective cable or wire. [Example]

[0063] The device of any one or more of Examples 1-10, wherein each protrusion of the plurality of protrusions extends proximally from the seal body. [Example]

[0064] The device of any one or more of Examples 1-11, wherein the sealing feature comprises a compatible material. [Example]

[0065] 13. The device of example 12, wherein the sealing feature comprises silicone. [Example]

[0066] The device of any one or more of Examples 1-13, wherein the sealing feature is integrated into the structure of the coupling member. [Example]

[0067] 15. The device of any one or more of Examples 1-14, wherein the sealing body includes a distal portion and a proximal portion, a gap defined between the proximal and distal portions, and a portion of the coupling member extending through the gap between the proximal and distal portions. [Example]

[0068] 1. A device comprising: a body; a shaft extending distally from the body; an end effector; a plurality of cables extending distally from the body through the shaft to the end effector; and a sealing feature disposed between the end effector and a portion of the shaft, the sealing feature including a sealing body and a plurality of protrusions extending from the sealing body, each protrusion of the plurality of protrusions configured to sealingly engage a corresponding cable while allowing movement of the respective cable relative to the shaft. [Example]

[0069] The device of Example 16, further comprising a wire extending from the body to the end effector, the wire configured to transmit RF energy from the body to the end effector, and one of the plurality of protrusions configured to slidably receive the wire. [Example]

[0070] The device described in Example 16 or 17, further comprising a clevis fixed to the distal end of the shaft, the clevis connecting the end effector to the distal end of the shaft to enable movement of the end effector relative to the shaft via actuation of a cable, and a sealing feature overmolded inside the clevis. [Example]

[0071] 1. A method of overmolding a sealing feature onto a clevis configured for use with a surgical instrument, the method comprising: positioning the clevis in a mold having a first mold portion and a second mold portion, the first mold portion including a pin having a free end extending toward and spaced from an opposing surface of the second mold portion; directing material into the mold and around the pin so that the pin defines a sealing hole in the sealing feature, thereby forming the sealing feature from the material, the sealing feature including a layer of material between the free end of the pin and the opposing surface of the second mold portion such that the layer of material is at an end of the sealing hole; after the material has hardened, removing the layer of material from the sealing feature to form an opening to the sealing hole; and coupling the clevis with the sealing feature to a distal end of a shaft assembly of the surgical instrument. [Example]

[0072] 20. The method of example 19, wherein the second mold part includes a gripping protrusion extending toward and facing the free end of the pin of the first mold part, and wherein removing the layer of material is performed by separating the first mold part from the second mold part such that the gripping protrusion peels the layer of material away from the sealing feature. [Example]

[0073] 20. The method of example 19, wherein the step of removing the layer of material is performed using a sharp punch. [Example]

[0074] 20. The method of example 19, wherein the step of removing the layer of material is performed using a laser cutter.

[0075] V. Other It should be understood that any one or more of the teachings, expressions, embodiments, examples, etc. described herein can be combined with any one or more of the other teachings, expressions, embodiments, examples, etc. described herein. Thus, the teachings, expressions, embodiments, examples, etc. described above should not be considered in isolation from one another. Various suitable ways in which the teachings herein can be combined will be readily apparent to those skilled in the art in light of the teachings herein. Such modifications and variations are intended to be within the scope of the claims.

[0076] It should be understood that all or part of any patent, publication, or other disclosure referred to herein as being incorporated by reference is incorporated herein only to the extent that the incorporated material does not contradict existing definitions, opinions, or other disclosures set forth in this disclosure. As such, and to the extent necessary, the disclosures explicitly set forth herein shall supersede any conflicting statements incorporated herein by reference. Any material, or portions thereof, that is referred to herein as being incorporated by reference but that contradicts current definitions, opinions, or other disclosures set forth herein shall be incorporated only to the extent that no conflict arises between the incorporated material and the current disclosures.

[0077] The device variations described above may be applied to traditional medical procedures and procedures performed by medical professionals as well as robotic-assisted medical procedures and procedures. By way of example only, the various teachings herein may be readily incorporated into robotic surgical systems such as the DAVINCI™ system by Intuitive Surgical, Inc. (Sunnyvale, California).

[0078] Variations of the devices described above may be designed to be disposed of after a single use, or they may be designed to be used multiple times. Variations, in either or both cases, may be reconditioned for reuse after at least one use. Reconditioning may include any combination of the steps of disassembly of the device, followed by cleaning or replacement of particular parts, and subsequent reassembly. In particular, some variations of devices may be disassembled, and any number of particular portions or parts of the device may be selectively replaced or removed in any combination. Upon cleaning and / or replacement of particular parts, some variations of devices may be reassembled for subsequent use at a reconditioning facility, or by a user immediately prior to a procedure. Those skilled in the art will appreciate that reconditioning of a device may utilize a variety of techniques for disassembly, cleaning / replacement, and reassembly. Use of such techniques, and the resulting reconditioned device, are all within the scope of the present application.

[0079] By way of example only, the variations described herein may be sterilized before and / or after the procedure. In one sterilization technique, the device is placed in a closed and sealed container, such as a plastic or TYVEK bag. The container and device may then be placed in a radiation field that can penetrate the container, such as gamma radiation, x-rays, or a high-energy electron beam. The radiation may kill bacteria on the device and in the container. The sterilized device may then be stored in the sterile container for later use. The device may also be sterilized using any other technique known in the art, including, but not limited to, beta or gamma radiation, ethylene oxide, or steam.

[0080] While various embodiments of the present invention have been shown and described, appropriate modifications by those skilled in the art may be made to further adapt the methods and systems described herein without departing from the scope of the present invention. While some such possible modifications have been mentioned, other modifications will be apparent to those skilled in the art. For example, the examples, embodiments, geometries, materials, dimensions, proportions, steps, etc. discussed above are illustrative and not required. Accordingly, it will be understood that the scope of the present invention should be considered in terms of the following claims, and is not limited to the details of construction and operation shown and described in the specification and drawings.

[0081] [Embodiment] (1) A device comprising: (a) a main body; (b) a shaft assembly extending distally from the body, the shaft assembly including a distal end; (c) an end effector; (d) a coupling member disposed at the distal end of the shaft assembly for movably coupling the end effector to the shaft assembly; (e) a sealing feature engaged with the coupling member, the sealing feature including a sealing body and a plurality of protrusions extending from the sealing body, each protrusion of the plurality of protrusions configured to slidably receive a respective elongated member associated with the end effector therethrough. (2) The device of embodiment 1, wherein each protrusion defines a receiving portion and a sealing portion, the sealing portion configured to sealingly engage the elongated member. (3) The device described in embodiment 2, wherein the sealing portion is configured to flex in response to lateral movement of the elongated member relative to the longitudinal axis of the shaft assembly. (4) The device described in embodiment 2, wherein the sealing portion is configured to flex in response to lateral movement of the elongated member relative to the longitudinal axis of the shaft assembly while maintaining sealing engagement with the elongated member. (5) The device of embodiment 1, wherein the sealing portion defines a sealing hole, the sealing hole defining a diameter approximately equal to the diameter of the elongated member.

[0082] (6) The device of claim 1, wherein the receiving portion defines a tapered bore extending therethrough and in communication with at least a portion of the sealing portion. (7) The device of embodiment 1, further comprising a plurality of cables extending from the body through the shaft assembly to the end effector, each cable being movable relative to the body to drive movement of the end effector, and each protrusion of the plurality of protrusions configured to slidably receive a corresponding cable to enable movement of the end effector via one or more cables of the plurality of cables. (8) The device of embodiment 7, wherein each protrusion is configured to bend laterally in response to lateral deflection of the corresponding cable via movement of the end effector. (9) The device of embodiment 1, further comprising a plurality of cables configured to drive the end effector and one or more wires configured to transmit RF energy to the end effector, wherein the plurality of cables and the one or more wires extend from the body through the shaft assembly to the end effector, one or more protrusions of the plurality of protrusions configured to slidably receive one of the plurality of cables, and one or more protrusions of the plurality of protrusions configured to slidably receive one of the one or more wires. (10) The device of embodiment 9, wherein each protrusion of the plurality of protrusions is configured to bend in response to lateral movement of a respective cable or wire.

[0083] (11) The device of embodiment 1, wherein each protrusion of the plurality of protrusions extends proximally from the seal body. (12) The device of claim 1, wherein the sealing feature comprises a compatible material. 13. The device of claim 12, wherein the sealing feature comprises silicone. (14) The device of claim 1, wherein the sealing feature is integrated into the structure of the coupling member. (15) The device of embodiment 1, wherein the sealing body includes a distal portion and a proximal portion, a gap is defined between the proximal portion and the distal portion, and a portion of the coupling member extends through the gap between the proximal portion and the distal portion.

[0084] (16) An apparatus comprising: (a) a main body; (b) a shaft extending distally from the body; (c) an end effector; (d) a plurality of cables extending distally from the body through the shaft to the end effector; (e) a sealing feature disposed between the end effector and a portion of the shaft, the sealing feature including a sealing body and a plurality of protrusions extending from the sealing body, each protrusion of the plurality of protrusions configured to sealingly engage a corresponding cable while allowing movement of the cable relative to the shaft. (17) The device of embodiment 16, further comprising a wire extending from the body to the end effector, the wire configured to transmit RF energy from the body to the end effector, and one of the plurality of protrusions configured to slidably receive the wire. (18) The device of claim 16, further comprising a clevis secured to the distal end of the shaft, the clevis connecting the end effector to the distal end of the shaft to enable movement of the end effector relative to the shaft via actuation of the cable, and the sealing feature being overmolded within the clevis. (19) A method of overmolding a sealing feature onto a clevis configured for use with a surgical instrument, comprising: (a) positioning the clevis in a mold having a first mold portion and a second mold portion, the first mold portion including a pin having a free end extending toward and spaced from an opposing surface of the second mold portion; (b) directing material into the mold and around the pin such that the pin defines a sealing hole in the sealing feature, thereby forming the sealing feature from the material, the sealing feature including a layer of material between the free end of the pin and the opposing surface of the second mold part such that the layer of material is at an edge of the sealing hole; (c) removing the layer of material from the sealing feature after the material has hardened to form an opening to the sealing hole; (d) coupling the clevis having the sealing feature to a distal end of a shaft assembly of a surgical instrument. (20) The method of claim 19, wherein the second mold part includes a gripping protrusion extending toward and facing the free end of the pin of the first mold part, and the step of removing the layer of material is performed by separating the first mold part from the second mold part such that the gripping protrusion peels the layer of material away from the sealing feature.

Claims

1. 1. An apparatus comprising: (a) a main body; (b) a shaft assembly extending distally from the body, the shaft assembly including a distal end; (c) an end effector; (d) a coupling member disposed at the distal end of the shaft assembly for movably coupling the end effector to the shaft assembly; (e) a sealing feature engaged with the coupling member, the sealing feature including a sealing body and a plurality of protrusions extending from the sealing body, each protrusion of the plurality of protrusions configured to slidably receive a respective elongated member associated with the end effector therethrough; The device, wherein the seal body includes a distal portion and a proximal portion, a gap defined between the proximal portion and the distal portion, the gap being formed by one or more internal structures of the coupling member extending through a hollow interior of the coupling member.

2. The device of claim 1 , wherein each projection defines a receiving portion and a sealing portion, the sealing portion configured to sealingly engage the elongate member.

3. The device of claim 2 , wherein the sealing portion is configured to flex in response to lateral movement of the elongated member relative to a longitudinal axis of the shaft assembly.

4. The device of claim 2 , wherein the sealing portion is configured to flex in response to lateral movement of the elongated member relative to a longitudinal axis of the shaft assembly while maintaining sealing engagement with the elongated member.

5. The device of claim 2 , wherein the sealing portion defines a sealing aperture, the sealing aperture defining a diameter approximately equal to a diameter of the elongated member.

6. The device of claim 2 , wherein the receiving portion defines a tapered bore extending therethrough and in communication with at least a portion of the sealing portion.

7. 2. The device of claim 1, further comprising a plurality of cables extending through the shaft assembly from the body to the end effector, each cable being movable relative to the body to drive movement of the end effector, and each protrusion of the plurality of protrusions configured to slidably receive a corresponding cable to enable movement of the end effector via one or more cables of the plurality of cables.

8. The device of claim 7 , wherein each protrusion is configured to bend laterally in response to lateral deflection of a corresponding cable via movement of the end effector.

9. 10. The device of claim 1, further comprising: a plurality of cables configured to drive the end effector; and one or more wires configured to transmit RF energy to the end effector, wherein the plurality of cables and the one or more wires extend from the body through the shaft assembly to the end effector, one or more protrusions of the plurality of protrusions configured to slidably receive a cable of the plurality of cables, and one or more protrusions of the plurality of protrusions configured to slidably receive a wire of the one or more wires.

10. 10. The apparatus of claim 9, wherein each protrusion of the plurality of protrusions is configured to bend in response to lateral movement of a respective cable or a respective wire.

11. The device of claim 1 , wherein each protrusion of the plurality of protrusions extends proximally from the seal body.

12. The device of claim 1 , wherein the sealing feature comprises a conformable material.

13. The device of claim 12 , wherein the sealing feature comprises silicone.

14. The device of claim 1 , wherein the sealing feature is integrated into the structure of the coupling member.

15. The device described in claim 1, wherein a portion of the coupling member extends through the gap between the proximal portion and the distal portion.

16. 1. An apparatus comprising: (a) a main body; (b) a shaft extending distally from the body; (c) an end effector; (d) a plurality of cables extending distally from the body through the shaft to the end effector; (e) a sealing feature disposed between the end effector and a portion of the shaft, the sealing feature including a sealing body and a plurality of protrusions extending from the sealing body, each protrusion of the plurality of protrusions configured to sealingly engage a corresponding cable while allowing movement of the cable relative to the shaft; a clevis secured to the distal end of the shaft; The device, wherein the seal body includes a distal portion and a proximal portion, a gap defined between the proximal portion and the distal portion, the gap being formed by one or more internal structures of the clevis extending through a hollow interior of the clevis.

17. 17. The device of claim 16, further comprising a wire extending from the body to the end effector, the wire configured to transmit RF energy from the body to the end effector, and one protrusion of the plurality of protrusions configured to slidably receive the wire.

18. The device described in claim 16, wherein the clevis connects the end effector to the distal end of the shaft to enable movement of the end effector relative to the shaft via actuation of the cable, and the sealing feature is overmolded inside the clevis.

19. 1. A method of overmolding a sealing feature onto a clevis configured for use with a surgical instrument, comprising: (a) positioning the clevis in a mold having a first mold portion and a second mold portion, the first mold portion including a pin having a free end extending toward and spaced from an opposing surface of the second mold portion; (b) directing material into the mold and around the pin such that the pin defines a sealing hole in the sealing feature, thereby forming the sealing feature from the material, the sealing feature including a layer of material between the free end of the pin and the opposing surface of the second mold part such that the layer of material is at an edge of the sealing hole; (c) after the material has hardened, removing the layer of material from the sealing feature to form an opening to the sealing hole; (d) coupling the clevis having the sealing feature to a distal end of a shaft assembly of the surgical instrument; the sealing feature includes a distal portion and a proximal portion, a gap defined between the proximal portion and the distal portion, the gap formed by one or more internal structures of the clevis extending through a hollow interior of the clevis.

20. 20. The method of claim 19, wherein the second mold part includes a gripping protrusion extending toward and facing the free end of the pin of the first mold part, and the step of removing the layer of material is performed by separating the first mold part from the second mold part such that the gripping protrusion peels the layer of material away from the sealing feature.

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