Abstract:
Forceps include a body, a surgical device, and a pair of handles. The surgical device is removably disposed within the body. The handles are pivotally attached to the handle body for articulating jaws on the surgical device, or grasping the forceps. The forceps accept monopolar, bipolar, or both monopolar and bipolar surgical devices. Wires are disposed within the surgical device for performing various types of electro-surgery. Additional wires are provided within the surgical device for providing the user with the ability to monitor various aspects of the surgical procedure. Spring contacts touch rings surrounding the surgical device for maintaining electrical contact with the surgical device while allowing the surgical device to rotate within the body.

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
       [0001]    The instant application claims priority to U.S. Provisional Patent Application Ser. No. 60/888,918, filed Feb. 8, 2007, and U.S. Provisional Patent Application Ser. No. 60/893,514, filed Mar. 7, 2007, the entire specifications of both of which are expressly incorporated herein by reference. 
     
    
     FIELD OF THE INVENTION 
       [0002]    The present invention generally relates to electrosurgical instruments and more specifically to adaptors and shafts for use with electrosurgical instruments. 
       BACKGROUND OF THE INVENTION 
       [0003]    Recent trends in electrosurgical instrumentation, both endoscopic and open surgery, require one or more conducting channels to control and monitor current and control desired functions which are related to active elements incorporated into advanced surgical instruments. 
         [0004]    Due to increased costs, sterilization requirements, and environmental considerations, there is a growing demand for active surgical devices, i.e., devices that have jaws for grasping, cutting, and/or dissecting, clamps, electrodes, and/or the like that may be disassembled and are adaptable. These devices may have one or more elements which are removable for cleaning or sterilization, disposal, interchangeability, or alterations. 
         [0005]    The electrical current types required for the elements of the surgical devices could be, but are not limited to monopolar and bipolar currents in all frequencies and wave forms and DC current. Conductive channels (e.g., wires) which have extra insulation may be useful to perform various measurements within the elements of the surgical devices, such as temperature measurement, current flow measurement, measurement of conductivity, measurement of resistance, impedance, pressure, liquid and gas flow, and/or the like. In other cases, power may be required for other types of elements, such as motors, heating elements, and/or the like. 
         [0006]    Accordingly, there exists a need for new and improved systems and methods for providing or constructing electrosurgical devices which are adaptable and/or active that overcome at least one of the disadvantages of the prior art. 
       SUMMARY OF THE INVENTION 
       [0007]    The present invention describes a system and a method to provide or construct surgical devices (e.g., electrosurgical devices) which are adaptable and/or active. The unique features of these devices are in the electrosurgical adaptors that allow attachment and detachment. In addition, sterilization of the elements and within compound shafts of the surgical devices may also be performed. Further, contacts and insulation arrangements within the adaptors, and related compound shafts, enable essential mechanical movements while being able to include a plurality of wire conductors. These wires convey currents and signals to and from the elements (e.g., jaws, tongs, electrodes, and/or the like). The specific designs of handles, adaptors, and compound shafts within the electrosurgical instruments permit unlimited rotation while allowing attachment/detachment of the elements from the electrosurgical instruments. 
         [0008]    More specifically, the present invention also discloses the necessary details to construct attachable/detachable, multi function, active surgical devices. The devices may be attached or detached to a surgical handle which provides a plurality of electrical and mechanical connections. The mechanical and electrical connections may activate and connect the devices via electrosurgical adaptors, contacts, connectors, wires, cables or shafts that are within the detachable surgical devices. The surgical devices could perform a variety of mechanical movements (e.g., grasping, dissecting, and/or shearing), be rotated beyond 360 degrees, and perform electro-cautery, electro-dissecting, coagulation, or homeostasis functions on a variety of tissue types. Further, these attachable/detachable devices may be equipped with extra electrical contacts and wires, which convey extra power, control and measurement to and from the elements of the electrosurgical devices, through the handle, via a generator. However, any other desired and related input or control unit may also be provided for use with the detachable devices. 
         [0009]    Further areas of applicability of the present invention will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating the preferred embodiment of the invention, are intended for purposed of illustration only and are not intended to limit the scope of the invention. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0010]    Other advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein: 
           [0011]      FIG. 1-1  shows a general cross-sectional side view of modular electrosurgical forceps, including an electrosurgical adaptor and a pair of handles; 
           [0012]      FIG. 1-2  shows an enlargement of detail area A of  FIG. 1-1 , showing a cross-section through the electrosurgical adaptor and adjacent handles; 
           [0013]      FIG. 2-1  shows a side view of the modular electrosurgical forceps; 
           [0014]      FIG. 2-2  shows an enlargement of detail area B of  FIG. 2-3 ; 
           [0015]      FIG. 2-3  shows a cross-sectional top view of the forceps taken along line A-A of  FIG. 2-1 ; 
           [0016]      FIG. 3-1  shows an enlarged cross-sectional view of the electrosurgical adaptor, configured for a bipolar application with two additional wires; 
           [0017]      FIG. 3-2  shows a transparent view of a detachable electrosurgical device, configured for a bipolar application with two extra wires and contacts; 
           [0018]      FIG. 3-3  shows another view of the bipolar detachable, electrosurgical device with two extra contacts and wires; 
           [0019]      FIG. 4-1  shows a side view of the electrosurgical adaptor with components shown in transparency and configured for the monopolar application with four extra contacts and wires; 
           [0020]      FIG. 4-2  shows a perspective view of the electrosurgical adapter with components shown in transparency, with four extra contacts and wires; 
           [0021]      FIG. 4-3  shows another perspective view of  FIG. 4-2  above; 
           [0022]      FIG. 4-4  shows an enlargement of detail area A of  FIG. 4-2 ; 
           [0023]      FIG. 5-1  shows a typical section through a compound bipolar shaft with two extra wires; 
           [0024]      FIG. 5-2  shows an assembly of a bipolar shaft and jaws, with two extra wires; 
           [0025]      FIG. 5-3  shows a conducting shaft connector; 
           [0026]      FIG. 5-4  shows a perspective view of a non-conducting shaft connector; 
           [0027]      FIG. 5-5  shows a perspective view of an assembly of a monopolar shaft and jaws, with four extra wires; 
           [0028]      FIG. 5-6  shows a partial perspective view of a compound monopolar shaft with four extra wires; 
           [0029]      FIG. 6-1  shows an elevational view of an adaptor body; 
           [0030]      FIG. 6-2  shows a sectional view taken along line A-A of  FIG. 6-1 ; 
           [0031]      FIG. 6-3  shows a perspective view of a spring contact; 
           [0032]      FIG. 6-4  shows a perspective view of a contact ring; 
           [0033]      FIG. 6-5  shows a perspective view of an adaptor body; 
           [0034]      FIG. 6-6  shows an enlargement of detail area B of  FIG. 6-2 ; 
           [0035]      FIG. 6-7  shows an enlargement of detail area C of  FIG. 6-1 ; 
           [0036]      FIG. 7-1  shows a cross-sectional side view of an alternative embodiment of the modular electrosurgical forceps, including an electrosurgical adaptor and a pair of handles; 
           [0037]      FIG. 7-2  shows enlargement of detail area A of  FIG. 7-1 , showing a cross-section through the electrosurgical adaptor and adjacent handles; 
           [0038]      FIG. 8-1  shows a cross-sectional view of a three-contact compound shaft of the alternative embodiment of  FIG. 7-1 ; 
           [0039]      FIG. 8-2  shows an isometric view of the compound shaft, contacts, wires and bipolar jaws of the alternative embodiment of  FIG. 7-1   
           [0040]      FIG. 8-3  shows an exploded isometric view of the elements of  FIG. 8-2  of the alternative embodiment of  FIG. 7-1 ; 
           [0041]      FIG. 8-4  shows a view of the contact ring and the wired connected to the contact ring; 
           [0042]      FIG. 9-1   a  shows a side view of a non-conductive core for use with two rings; 
           [0043]      FIG. 9-1   b  shows an end view of a non-conductive core for use with two rings; 
           [0044]      FIG. 9-1   c  shows a perspective view of the non-conductive core for use with two rings; 
           [0045]      FIG. 9-2  shows a perspective view of an alternative non-conductive core for use with four rings; 
           [0046]      FIG. 9-3   a  shows a front perspective view of an adapter; 
           [0047]      FIG. 9-3   b  shows a rear perspective view of an adapter; 
           [0048]      FIG. 9-3   c  shows an end view of an adapter; 
           [0049]      FIG. 9-3   d  shows a sectional view taken along line A-A of  FIG. 9-3   c ; and 
           [0050]      FIG. 9-4  shows a perspective view of a contact ring. 
       
    
    
       [0051]    The same reference numerals refer to the same parts throughout the various Figures. 
       DETAILED DESCRIPTION OF THE INVENTION 
       [0052]    The following description of the preferred embodiment(s) is merely exemplary in nature and is in no way intended to limit the invention, or uses. Referring to the Figures generally, wherein like numerals indicate like parts throughout the several views, and specifically to  FIG. 1 , an electrosurgical forceps is shown generally shown at  1 . 
         [0053]    The forceps  1  include a handle body  4 , a surgical device  2 , and a pair of handles  9 ,  10 . The surgical device  2  is removably disposed within the handle body  4 . The handles  9 ,  10  are pivotally attached to the handle body for articulating jaws  47 ,  48  on the surgical device  2 , or grasping the forceps  1 . 
         [0054]    The surgical device  2  includes an adaptor body  3 , preferably from non-conductive material such as polymer or ceramic, which is attached to the handle body  4  via a locking piece  5 , as shown in  FIG. 1-2 . The adaptor body  3  defines a hollow passage  6 . The hollow passage  6  allows reciprocal movements of compound shaft assembly  7  within a tubular element  8 . Reciprocal movements are caused by closing or opening the handles  9  and  10  with respect to one another. When the handles  9  and  10  care closed, a stem assembly  11  is pulled proximally via links  12  and  13  and the retreat of a collet  14 , which pulls an end  27  of compound shaft assembly  7  proximally. 
         [0055]      FIG. 1-2  is a cross-section view, taken through the handle body  4  and the adaptor body  3 , which shows a power plug assembly  15 . The electrosurgical adaptor body  3  includes two contact rings  16  and spring contacts  17 . Insulated wires  18 ,  19 ,  20 , respectively, that are connected with axial rings  21 ,  22 ,  23 , respectively, carry current from the power plug assembly  15  to a collet housing  24  and body spring contacts  25 ,  26 . 
         [0056]    Spring contacts  25 ,  26 , and the collet housing  14 , carry current to the contact rings  16  and the collet  14 , respectively. Spring contacts  17 , disposed within the adaptor body  3 , carry currents to shaft conducting connectors and an end  27  of the compound shaft  7 . 
         [0057]    Torque is applied to the tubular element  8  or a rotation knob  28 , shown in  FIG. 2-1 , which allows the surgical device  2  to rotate within handle body  4  while retaining continuous contacts from the power plug assembly  15  through the wires, housing, contacts and/or conductors. Therefore, independent currents may be conveyed via the incorporation of extra wires  33 ,  34  for other functions as stated above (e.g., see  FIG. 2-3 ). 
         [0058]      FIG. 2-2  shows a monopolar activating shaft  29 , attached to an end  27  of the compound shaft assembly  7 . The activating shaft  29  causes opening and closing of jaws  30 ,  31 , via links  32 , which act in concert with relative positions of the handles  9 ,  10  and a mechanical train, i.e., links  12 ,  13 , stem assembly  11 , collet  14 , and/or the like. 
         [0059]      FIGS. 3-1 ,  3 - 2 , and  3 - 3  show details of another example, in this case, a bipolar detachable device with two extra wire channels. Additionally, the handle body may be constructed to allow an insulated passage for a plurality of the conductive wires. 
         [0060]    In this specific case, the adaptor body  35 , carrying three contact rings  37 ,  38 ,  39 , is housing a compound shaft  45  as shown. The shaft end  40  receives a positive current and is attached to conductive, insulated wire  41 , driving link  46  and causing movement of jaw  47 , rotated on insulated pin  49 . Negative wire  42  similarly drives jaw  48  via link  50 . Thus, while retaining insulation throughout, except when contacts are required for continuity, jaws  47 ,  48  will be charged in a bipolar fashion. Extra wires  43  and  44  allow other desired functions, as mentioned earlier, to be performed. 
         [0061]      FIGS. 4-1 ,  4 - 2 ,  4 - 3 , and  4 - 4  show another embodiment of a monopolar electrosurgical attachable device  51 , where a compound shaft end  52  is connected to a positive electrical source via a handle body. Four contact rings  53  allow for the connection and/or application of other desired functions. 
         [0062]      FIGS. 5-1  and  5 - 2  show a bipolar compound shaft  110  with two extra wires  58 ,  59 . When an end  54  of the compound shaft  110  is securely attached to a non-conducting shaft connector  55 , the whole shaft assembly and other wires,  57 ,  58 ,  59  are advanced within the adaptor body. The wires  56  and  57  activate and charge the jaws  47 ,  48 , while the wires  58  and  59  are available for other tasks. Note that shaft end  54  and non-conductive and conductive connectors  55 ,  60 , respectively, are attached rigidly. 
         [0063]      FIGS. 5-5  and  5 - 6  show a construction of a monopolar compound shaft  110 . 
         [0064]      FIGS. 6-1  through  6 - 7  show a non-conductive adaptor body  61 , defining a circumferential locking groove  62  and a contact ring groove  63 . The adaptor body  61  defines a hole  66  within the contact ring groove  63 . A spring contact  65 , as illustrated in  FIG. 6-3 , is seated within the hole  66 . A contact ring  64  (e.g., see  FIG. 6-4 ) contacts and compresses the spring contact  65  within the hole  66  to conduct current to or from the compound shaft  100 ,  110 , within a passage, defined in the adaptor body  61 . 
         [0065]      FIG. 7-1  shows a cross-sectional side view through an alternative embodiment of the modular electrosurgical forceps  300 . The forceps  300  include a detachable endoscopic bipolar surgical device  302 . The surgical device  302  of this embodiment is rotatable, while maintaining electrical contact. The surgical device  302  includes an adaptor body  303 , preferably formed from non-conductive material such as polymer or ceramic, which is attached to a handle body  304  via a locking piece  305 , as shown in  FIG. 7-2 . The adaptor body  303  defines a hollow passage  306 . The hollow passage  306  allows reciprocal movements of a compound shaft assembly  307  within a tubular element  308 . The reciprocal movements result from closing and/or opening the handles  9 ,  10 . In this embodiment, closure of the handles  9 ,  10  causes the stem assembly  311  to be pulled proximally via links  312  and  313 . As the links  312 ,  313  pull the stem assembly  311  proximally, the stem assembly  311  pulls a collet  314  proximally. The collet  314 , which grasps the compound shaft  307 , pulls the compound shaft  307  proximally. 
         [0066]      FIG. 7-2  shows an enlarged cross-sectional view taken through the handle body  304  and the adaptor body  303 . Insulated wiring  202 ,  203  connect to spring contacts  204 ,  205 , respectively. The spring contacts  204 ,  205  touch contact rings  316 , disposed on the compound shaft  307 . Therefore, the adaptor body  303  of the forceps  300  includes two contact rings  316  and spring contacts  317 . Insulated wire  201  connects to a collet contact  206 . The collet contact  206  extends into a groove  323  defined by a collet housing  324 . The collet housing  324  is disposed within the hollow passage  306 . The collet housing  324  is formed from a metallic, or other conductive material. The contact rings  207  are connected to wires  208 ,  209 . A cable end  210 , which extends from the compound shaft  307 , is conductive and conveys current to wire  211 . 
         [0067]    Referring to  FIG. 8-4 , a typical contact assembly  212  is shown. The assembly  212  includes a contact ring  207  which is connected to an insulated wire  208 . The insulated wire  208  includes an end which is exposed and soldered, crimped, welded, or otherwise attached to the contact ring  207 . 
         [0068]    Referring to  FIGS. 8-1  and  8 - 2 , the compound shaft assembly  307  is shown. The compound shaft assembly  307  includes a cable end  210  which is connected to a non-conductive core  217 . Two contact rings  207  are placed in recesses  218  which are defined in the non-conductive core  217 , as shown generally in  FIG. 2-3 . Wires  215 ,  216  are disposed within grooves  219 , defined along the non-conductive core  217 .  FIG. 8-3  shows an exploded isometric view of the compound shaft assembly  307 . A wire  216  is attached the contact ring  207  and extends underneath the contact ring  207 , located distally from the contact ring  207 . Additionally, a wire  215  is attached to the contact ring  207 . 
         [0069]    An adaptor  213  is normally snapped, or otherwise attached, at a distal end of the compound shaft assembly  307  to secure wires  215 ,  216  which are bent, as shown in  FIG. 8-3 . This reduces flexure of the bent portions  220 . 
         [0070]      FIGS. 9-1   a ,  9 - 1   b , and  9 - 1   c  show various views of the non-conductive core  217 .  FIG. 9-2  shows another embodiment of a non-conductive core  217  which defines four recesses  218  and a through-hole. The additional two recesses allow the non-conductive core  217  to be assembled for up to five live wires. 
         [0071]      FIGS. 9-3   a - d  shows views of the adaptor  213 , preferably from non-conductive, elastic material.  FIG. 9-4  shows a typical contact ring  207  defining a slot  214 . The contact ring  207  is preferably formed from elastic, conductive material, which allows it to be resilient such that it expands over the non-conducting core  217  and snaps back to its original size while resting in the recess  218 . 
         [0072]    While the invention has been described with reference to an exemplary embodiment, it will be understood by those skilled in the art that various changes can be made and equivalents can be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications can be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims.