ELECTROSURGICAL DEVICES WITH FLUID FLOW CONTROL

The disclosure provides various electrosurgical devices comprising a handle assembly comprising a valve having an input port and an output port. The input port is fluidically coupled to either an irrigation source or a suction source. At least one button is operatively coupled to the valve to control flow through the valve. At least one switch is provided to electrically couple energy from an energy source. A trigger and a shaft comprising a slidable element is operatively coupled to the trigger. An electrode is electrically coupled to the switch. The trigger is operable to position the slidable element relative to the electrode to conceal or expose the electrode. The handle assembly may comprise an articulating joint. The handle assembly may comprise a trigger lockout mechanism.

BACKGROUND

The present disclosure is related generally to electrosurgical devices with various mechanisms for controlling fluid flow. In particular, the present disclosure is related to electrosurgical devices with various mechanisms for controlling fluid flow, such as, irrigation and suction fluid flow, for example. More particularly, the present disclosure is related to electrosurgical devices with articulating manifolds and various mechanisms for controlling fluid flow, such as irrigation and suction fluid flow, for example.

While several devices have been made and used, it is believed that no one prior to the inventors has made or used the device described in the appended claims.

SUMMARY

In one embodiment, an electrosurgical device comprises a handle assembly comprising: a valve having an input port and an output port, the input port fluidically coupled to either an irrigation source or a suction source; at least one button operatively coupled to the valve to control flow through the valve; at least one switch to electrically couple energy from an energy source; and a trigger; a shaft comprising: a slidable element operatively coupled to the trigger; and an electrode electrically coupled to the switch; wherein the trigger is operable to position the slidable element relative to the electrode to conceal or expose the electrode.

In another embodiment, an electrosurgical device comprises a handle assembly defining a rigid wall; a cam arm supported by the handle assembly and pivotally movable about a first pivot on one side and comprising a roller supported on another side, the cam arm defining a slot therebetween; a first button supported by the handle assembly and pivotally movable about a second pivot, the first button comprising: an arm; and a projecting tab slidably engaged with the slot; a second button pivotally coupled to the cam arm at the first pivot; and a bias element acting on the arm of the first button to force the cam arm to pivotally move in a first direction and the roller to move toward the rigid wall of the handle assembly; wherein pressing the first button overcomes the force of the bias element and the projecting tab applies a force on the slot to pivotally move the cam arm in a second direction and to move the roller away from the rigid wall of the handle assembly.

In yet another embodiment, an electrosurgical device comprises a handle assembly comprising an articulating handle comprising a proximal housing and a distal housing rotatably coupled at an articulation joint; a sealed fluid flow manifold assembly configured to articulate about the articulation joint; and a locking mechanism positioned at the articulation joint to lock the proximal housing and the distal hosing in a configuration.

In addition to the foregoing, various other method and/or system and/or aspects are set forth and described in the teachings such as text (e.g., claims and/or detailed description) and/or drawings of the present disclosure.

The foregoing is a summary and thus may contain simplifications, generalizations, inclusions, and/or omissions of detail; consequently, those skilled in the art will appreciate that the summary is illustrative only and is NOT intended to be in any way limiting. Other aspects, features, and advantages of the devices and/or processes and/or other subject matter described herein will become apparent in the teachings set forth herein.

DESCRIPTION

Before explaining the various embodiments of the surgical devices with close quarter articulation features in detail, it should be noted that the various embodiments disclosed herein are not limited in their application or use to the details of construction and arrangement of parts illustrated in the accompanying drawings and description. Rather, the disclosed embodiments may be positioned or incorporated in other embodiments, variations and modifications thereof, and may be practiced or carried out in various ways. Accordingly, embodiments of the surgical devices with close quarter articulation features disclosed herein are illustrative in nature and are not meant to limit the scope or application thereof. Furthermore, unless otherwise indicated, the terms and expressions employed herein have been chosen for the purpose of describing the embodiments for the convenience of the reader and are not to limit the scope thereof. In addition, it should be understood that any one or more of the disclosed embodiments, expressions of embodiments, and/or examples thereof, can be combined with any one or more of the other disclosed embodiments, expressions of embodiments, and/or examples thereof, without limitation.

Also, in the following description, it is to be understood that terms such as front, back, inside, outside, top, bottom and the like are words of convenience and are not to be construed as limiting terms. Terminology used herein is not meant to be limiting insofar as devices described herein, or portions thereof, may be attached or utilized in other orientations. The various embodiments will be described in more detail with reference to the drawings.

The embodiments described herein provide electrosurgical devices with electrical energy driven tissue sealing (e.g., cauterization) or treatment (e.g., non-reversible electroporation) functionality as well as irrigation and suction functionalities. The electrosurgical devices include handle assemblies that are ergonomically easy to use for the operator (e.g., surgeon). The handle assemblies include suction and irrigation buttons that are easy to press, shaft knobs that are easy to rotate, and energy buttons that are easy to activate making it easy for the device to switch between multiple modes of operation. The suction and irrigation buttons, shaft knobs, and energy activation buttons according to the disclosed embodiments can be manipulated with reduced force and can be operated with one hand to control irrigation and suction, manipulate and rotate the shaft knob, and activate energy.

In various embodiments, electrosurgical devices are provided that can be operated without requiring the operator to manually push/pull the irrigation and suction nozzle or sheath forward/backward to conceal/expose a distal electrode tip during irrigation and suction/cauterization processes. Pushing the nozzle forward or pulling it back is not ergonomic and does not allow the operator to have fine control over the extension of the shaft. Accordingly, various mechanisms are disclosed to improve the ergonomics functionality of such electrosurgical instruments to allow for better shaft extension/retraction, irrigation and suction, and energy activation control.

Accordingly, the various embodiments described herein provide for single hand use of all controls, easier transition between irrigation/suction and electrocautery modes, and more control of how far a monopolar electrode tip is exposed.

Embodiments with Valve Manifold

In one embodiment, an electrosurgical device comprises a fluid flow manifold with valves to make the operation of fluid flow control buttons easier to press during a surgical procedure. In one embodiment, for example, the fluid flow control buttons control the operation of irrigation and suction valves. The valves may be stopcock valves or other types of valves that are operatively attached to the buttons. The control buttons convert linear motion to rotational motion to rotate the valves enough to open and close them. The stopcock valves require low force required to push the buttons as well as the travel needed. Also, a trigger is provided to extend and retract the shaft knob. The trigger may be attached to a lever arm so that the motion of the trigger matches the motion of the knob. In one embodiment, when the trigger is out (distal) the shaft knob is out (distal) and when the trigger is in (proximal) the shaft knob is in (proximal). The motion matching lever arm may be attached to a slide. The slide may be attached to the shaft as well as to an electrosurgical probe electrode. The trigger also may be attached to a spring to allow for easy return of the trigger to its starting position (e.g., from a proximal position when the trigger is squeezed by the operator to a distal position when the operator releases the trigger). Accordingly, the controls for operating the electrosurgical treatment, cauterization, and/or fluid flow functions, such as irrigation/suction functions, for example, may be comfortable and easy to use for the operator. In one embodiment, an energy button used to activate the electrosurgical function may be located on top of the handle assembly and the irrigation/suction buttons may be located in front of the handle assembly such that when the trigger is extended outwardly (distal) it makes is easier for the operator to press the irrigation/suction buttons. When the trigger is located in a retracted inwardly position (proximal) it makes it easier for the operator to actuate the energy button and the suction button simultaneously. In addition, the disclosed embodiments enable the control elements (e.g., irrigation/irrigation buttons, energy switch, trigger, etc.) to be manipulated with one hand.

In one embodiment, an electrosurgical device comprises suction, irrigation, and energy delivery combination with an extending and retracting shaft coupled to a movement element of a trigger. The motion and/or direction of the trigger matches the motion and/or direction of the moving shaft. The trigger may couple to the shaft through a set of lever arms and/or cam surfaces. The trigger may couple to the shaft through a set of gears. In another embodiment, the trigger is spring returned. The suction and irrigation valves may be rotational stopcocks coupled to linear motion buttons. In various embodiments, the energy delivery system of the electrosurgical device may employ radio frequency (RF) energy to treat and/or cauterize tissue in monopolar or bipolar energy modes. In various embodiments, the handle assembly may have a pistol grip configuration, a pencil grip configuration, or may be configured to articulate between a pistol grip and a pencil grip and vice-versa. These embodiments are described hereinbelow in connection withFIGS. 1-31.

FIG. 1depicts a perspective view of an electrosurgical device10comprising a handle assembly12, a shaft portion14, and an electrode24. The electrosurgical device10comprising irrigation and suction features and a slidably movable element to control exposure of the electrode portion24of the electrosurgical device10, according to one embodiment.

The handle assembly12is configured as a pistol grip and comprises left and right handle housings or shrouds16a,16b, a rotatable shaft knob18, a trigger20, an energy button26or switch, a first flow control button, e.g., an irrigation button28, and a second flow control button, e.g., a suction button30. Irrigation and suction tubes32,34and an electrical cable36enter the handle assembly12through a bottom portion. The shaft portion14comprises a slidable sheath22that extends distally and retracts proximally to respectively conceal and expose the electrode portion24. The slidable sheath22is operatively coupled to the trigger20. The irrigation and suction tubes32,34are fluidically coupled to a manifold and respective valves located within the space created between the left and right housing portions16a,16bof the handle assembly12. The irrigation and suction buttons28,30control stopcock valves located within the manifold to control the flow of irrigation fluid through the irrigation tube32and suction through the suction tube34. The electrical cable36is electrically coupled to the energy switch26and an energy source8. The energy source8may be a monopolar or bipolar RF energy source. The energy source8may be suitable for therapeutic tissue treatment as well as tissue cauterization/sealing. The energy switch26controls the delivery of energy to the electrode24. A detailed explanation of each of these control elements is provided hereinbelow. As used throughout this disclosure, a button refers to a switch mechanism for controlling some aspect of a machine or a process. The buttons may be made out of a hard material such as usually plastic or metal. The surface may be formed or shaped to accommodate the human finger or hand, so as to be easily depressed or pushed. Buttons can be most often biased switches, though even many un-biased buttons (due to their physical nature) require a spring to return to their un-pushed state. Terms for the “pushing” of the button, may include press, depress, mash, and punch.

FIG. 2depicts a perspective view of the handle assembly12of the electrosurgical device10shown inFIG. 1, according to one embodiment. The shaft knob18of the handle assembly12shown inFIG. 2is extended distally along a slide element40, which encases a nozzle44fluidically coupled to a manifold located within the handle assembly12. As will be described in more detail below, the slide element40element is operatively coupled to the trigger20. The trigger20is shown extended in a first “initial” position (e.g., extended distally in direction E) under the influence of a biasing element such as a spring. The position of the trigger20shown inFIG. 2may be referred to herein as the initial or original position in which the trigger20is normally configured in and may automatically return to unless a trigger lockout mechanism is provided to prevent automatic return to the initial position. A shaft lock button42is provided to lock the shaft portion14(FIG. 1) in place. The shaft knob18and slide element40are operatively coupled to the slidable sheath22(FIG. 1) to conceal and/or expose the distal electrode24(FIG. 1).

FIG. 3depicts a perspective view of the shaft portion14of the electrosurgical device10show inFIG. 1configured to couple to the handle assembly12of the electrosurgical device10shown inFIG. 1, according to one embodiment.

With reference toFIGS. 1-3, the slidable sheath22is coupled to the shaft knob18at a proximal end and is slidable longitudinally to control the exposure of the electrode24. In one embodiment, when the trigger20(FIG. 2) is extended outwardly in a distal position, the slidable sheath also is extended outwardly in a distal position to conceal the electrode24. In this mode, the electrode24is isolated from tissue and thus the application of energy to the electrode24does not affect the tissue. In the same embodiment, when the trigger20is squeezed by the operator inwardly in a proximal position, the slidable sheath22is retracted to expose the electrode24. Once the electrode24is exposed, the energy switch may be activated to apply energy to any tissue in contact with the electrode24. In other embodiments, the operation may be opposite of that described above in connection with the disclosed embodiment such that when the trigger20is extended distally, the electrode24is exposed and when the trigger20is squeezed proximally, the electrode24is concealed.

FIG. 4depicts a side elevational view of the handle assembly12of the electrosurgical device10shown inFIG. 1where the trigger20portion is shown in a second position (e.g., squeezed proximally in direction A) such that the slidably movable element, e.g., the slidable sheath22(FIGS. 1 and 3) is in a retracted position, according to one embodiment. When the trigger20is in the extended position the slidable sheath22is retracted proximally. This position enables the energy to be applied to the distal electrode24(FIGS. 1 and 3) by activation of the energy switch26.

FIG. 5depicts a distal end view of the shaft portion14of the electrosurgical device shown inFIG. 1that is coupled to the handle assembly12of the electrosurgical device10shown inFIG. 4, where the slidably movable sheath22is in the retracted position to expose the electrode24, according to one embodiment. The distal portion of the slidable sheath22also defines fluid flow ports38(e.g., irrigation/suction flow ports) delivering fluids to the surgical site or suctioning fluid therefrom.

FIG. 6depicts a side elevational view of the handle assembly12of the electrosurgical device10shown inFIG. 1where the trigger20is in the first position (e.g., extended distally in direction E) such that the slidably movable element, e.g., the slidable sheath22(FIGS. 1 and 3) is in an extended position in direction D to conceal the electrode24, according to one embodiment. The trigger20is sprung forward distally to enter the different fluid flow modes (e.g., irrigation/suction modes). The nozzle44(FIG. 2) moves forward distally over the electrode24tip to conceal it. In one example, the irrigation and suction fluid flow control buttons32,34are shown pressed in with a predetermined travel distance. In one embodiment, the irrigation and suction buttons32,34may travel up to 2 inches.

FIG. 7depicts a distal end view of the shaft portion14of the electrosurgical device shown inFIG. 1that is coupled to the handle assembly12of the electrosurgical device10shown inFIG. 6, with a slidably movable sheath22in the extended position to conceal the electrode24, according to one embodiment. In the irrigation/suction mode, the irrigation/suction fluid flow ports38are employed to deliver fluids to the surgical site or suction fluid therefrom.

FIG. 8depicts an exploded view of the handle assembly12of the electrosurgical device10shown inFIG. 1, according to one embodiment. This view shows the components of the valve manifold located within the handle assembly12. The left and right shrouds16a,16b(handle housings) provide a support for the irrigation and suction fluid flow control buttons28,30, the trigger20, and the slide element40. In addition, the left and right shrouds16a,16balso support a valve manifold48that is fluidically coupled to the irrigation and suction ports32,34as well as the nozzle44. The left and right shrouds16a,16balso support the energy switch26and a circuit board element84as well as the electrical cable36.

In one embodiment, the valve manifold48is configured to rotatably support an irrigation valve50and a suction valve54. Although the irrigation and suction valves50,54are stopcock valves, other suitable valves may be employed without departing from the scope of the present disclosure. Irrigation valve O-rings52are located about grooves provided on the outer surface of the irrigation valve50. Suction valve O-rings56are located about grooves provided on the outer surface of the suction valve54. The irrigation and suction valves50,54include tabs or drive dogs that engage respective slots76,78formed on linear arm portions of the respective irrigation and suction buttons28,30. The valve manifold48also includes an O-ring58and a washer60. A retainer clip62that also acts as an electrical spring contact retains the valve manifold48to the right shroud16b. Irrigation and suction ports64,66are used to fluidically couple the valve manifold48to the irrigation tube32and suction hose80, which is fluidically coupled to the suction tube coupling34. The valve manifold48is supported within the handle assembly12by a pin74which is received within corresponding holes formed in each shroud16a,16b.

The irrigation and suction buttons28,30(flow control buttons) each include a spring68,70to bias and return the buttons28,30to the distal position after being actuated.

A reversing lever arm46is pivotally coupled to the right shroud16a,16bvia a pin72. A first projecting tab94is received within a corresponding hole in the right shroud16band a second projecting tab92is engaged by a corresponding notch96formed in a lever arm95portion of the trigger20. The lever arm95includes a pivot hole86about which the trigger20rotates. The reversing lever arm46is operatively coupled to the slide knob40, which is operatively coupled to the slidable sheath22(FIGS. 1,3,5,7) of the shaft portion14(FIGS. 1,3,5,7). The notch96in the lever arm95of the trigger20engages the second projecting tab92of the reversing lever arm46to cause the motion of the slide knob40to match the motion of the trigger20, e.g., trigger20forward—slide knob40forward and trigger20backward—slide knob40backward. The slide knob40is slidably movable over the nozzle44, which is fluidically coupled to the output port of the valve manifold48. A torsion spring82is located over a hub90formed in the right shroud16b. One arm of the torsion spring82is coupled to a slot88formed in the lever arm95portion of the trigger20and another arm of the torsion spring82is located against a back wall of the right shroud16bto bias the trigger20outwardly in a distal position when not squeezed and to return the trigger20outwardly to the distal position when the operator releases the trigger20.

The circuit board84is mounted to the right shroud16b. The energy switch26is electrically coupled to the circuit board84. The electrical spring contact62also is electrically coupled to the circuit board84. The electrical spring contact62is electrically coupled to the electrode24(FIGS. 1,3,5). The electrical cable36couples energy from the energy source to the circuit board84. When the energy switch26is activated energy is coupled from the energy source to the electrode24via the electrical spring contact62.

FIG. 9depicts a partial cut-away transparent side elevational view of the handle assembly12of the electrosurgical device10shown inFIG. 1with the irrigation and suction buttons28,30pushed out by the corresponding irrigation and suction button springs68,70to disable fluid flow, according to one embodiment.

FIG. 10depicts a partial cut-away transparent side elevational view of the handle assembly12of the electrosurgical device10shown inFIG. 1with the irrigation and suction buttons28,30pushed in to enable fluid flow, according to one embodiment.

With reference now toFIGS. 9 and 10, the slots76,78formed in the arm portions of the irrigation and suction buttons28,30engage projecting tabs124,126(FIGS. 15,17,18) on the stopcock valves50,54. When the buttons28,30are positioned outwardly as shown inFIG. 9, the valves50,54are positioned in a closed position to block flow. When the buttons28,30are pressed, the slots76,78act on the corresponding tabs124,126on the valves50,54and rotate the valves50,54from a closed position to an open position as shown inFIG. 10to enable flow through the valves50,54.

FIG. 11depicts a partial cut-away transparent side elevational view of the handle assembly12of the electrosurgical device10shown inFIG. 1with the reversing lever arm46operatively coupled to the trigger20where the trigger20is located in a forward (distal) position as biased by the torsion spring82to extend the slide element40forward in a distal direction to conceal the electrode24(FIGS. 1,3,5), according to one embodiment. The torsion spring82returns the trigger20. The torsion spring82is located over the hub90and one arm is coupled to the lever arm85portion of the trigger20at the slot88and another arm is positioned against a hard wall portion of the right shroud16bto provide resistance when the trigger20is squeezed. As shown inFIG. 9, the torsion spring82is in tension mode to bias the trigger outwardly in a distal direction. The reversing lever arm46is pivotally coupled to the right shroud16bby the pin72. The lever arm85portion of the trigger20is pivotally coupled at pivot86to the right shroud16bby the pin74. The notch96formed in the lever arm85portion of the trigger20engages the projecting tab92of the reversing lever arm46. As shown inFIG. 9, the reversing lever arm46applies a pushing force to the slide knob44to maintain the slidable sheath22(FIG. 7) in a distal direction to conceal the electrode24.

FIG. 12depicts a partial cut-away transparent side elevational view of the handle assembly12of the electrosurgical device10shown inFIG. 11with the trigger20in a backward (proximal) position squeezed to overcome the bias force of the torsion spring82to retract the slide element40backward in a proximal direction to expose the electrode24(FIGS. 1,3,5), according to one embodiment. As the trigger20is squeezed, the lever arm85portion rotates counterclockwise about the pivot point86and the notch96applies a pushing force to the projecting tab92of the reversing lever arm46causing the reversing lever arm46to rotate clockwise applying a pulling force to the slide knob44to retract the slidable sheath22(FIG. 1,3,5) in a proximal direction to expose the electrode24and enable energy to be applied to tissue contacting the electrode24at the surgical site.

With reference toFIGS. 11 and 12, the reversing lever arm46enables the motion direction of the trigger20to match the motion direction of the slide knob44, and hence, the motion direction of the slidable sheath22. In accordance with the illustrated embodiment, when the trigger20is forward the slide knob40is forward and when trigger20is back the slide knob44is back.

FIG. 13depicts a transverse sectional view of the handle assembly12of the electrosurgical device10shown inFIG. 1to further illustrate the operation of the irrigation and suction valves50,54, according to one embodiment. As shown inFIG. 13, when the suction valve54is pushed to the far right by squeezing the suction button30, the force required to rotate the valve54within the valve manifold48and open the suction valve port98is centered on the button30. The irrigation button/irrigation valve operates in a similar manner.

FIG. 14depicts a longitudinal sectional view of the handle assembly12of the electrosurgical device10shown inFIG. 1to further illustrate the operation of the irrigation and suction valves50,54, according to one embodiment. The valve manifold48is fluidically coupled to the irrigation tube32via the irrigation port64and to the suction tube80via the suction port66. The valve manifold48includes an irrigation channel102and a suction channel104. The irrigation tube32is fluidically coupled to the irrigation channel102via the irrigation valve50. When the irrigation button28is depressed, the irrigation valve50rotates such that the irrigation valve port100fluidically couples the irrigation tube32to the irrigation channel102and causes irrigation fluid to flow to the main flow channel106and through the nozzle44down to the irrigation ports38at the distal end of the shaft portion14(FIGS. 3,5). When the irrigation button28is released (as shown), the irrigation valve50blocks the flow. The suction tube80,34is fluidically coupled to the suction channel104via the suction valve54. When the suction button30is depressed, the suction valve54rotates such that the suction valve port108fluidically couples the suction tube80,34to the suction channel104and causes suction fluid to flow from the irrigation ports38at the distal end of the shaft portion14through the nozzle44and the main flow channel106through the suction channel104, the suction valve port109, and the suction tubes80,34.

FIG. 15depicts a partial cut-away transparent view of the handle assembly12of the electrosurgical device10shown inFIG. 1to illustrate electrical wiring connections between an energy cable36, an energy switch circuit board84of the energy switch26, and an electrical contact spring62according to one embodiment.

FIG. 16depicts a right side perspective view of the handle assembly12of the electrosurgical device10shown inFIG. 15to illustrate the wiring between the energy cable36and the circuit board84of the energy switch26, according to one embodiment.

With reference to bothFIGS. 15 and 16, the energy cable36coupled to the energy source enters through a bottom portion of the handle assembly12. Electrical wires108from the cable36are routed to and electrically connected to the circuit board84. The energy switch26is electrically connected to the circuit board84. Another electrical wire109is electrically connected between the circuit board84and the electrical contact spring62. The electrical contact spring62is electrically connected to the electrode24(FIGS. 1,3,5).

FIG. 17depicts an exploded view of a valve manifold assembly130, according to one embodiment. The valve manifold assembly130comprises a valve manifold48, valves50,54, and seals. The valve manifold48includes irrigation and suction ports64,66to fluidically couple the valve manifold assembly130to irrigation and suction tubes. The valve manifold48also defines apertures110,112to rotatably receive the respective irrigation and suction valves50,54therein. O-ring seals52are located over grooves118,128formed about an outer surface of the irrigation valve50. O-ring seals56are located over grooves120,122formed about an outer surface of the suction valve54. The irrigation valve50includes an irrigation valve port100and the suction valve54includes a suction valve port98. Each valve50,54also includes a projecting tab124,126that engages corresponding slots76,78in the arm portions of the irrigation and valve buttons28,30(FIGS. 8-12,15).

Once the O-rings52,56are applied on the valves50,54the valves50,54are inserted into the valve apertures110,112of the valve manifold48. The O-rings52,56may be omitted when using solid valves. O-ring58is inserted into a port of the valve manifold and a washer60is welded into place over the O-ring58.

FIG. 18depicts a perspective view of an assembled valve manifold assembly130shown inFIG. 17, according to one embodiment. Mounting holes114,116are provided to mount the valve manifold assembly130within the handle assembly12.

FIG. 19depicts a button28,30to operate either the irrigation and/or suction functions, according to one embodiment. The button28,30comprises a button body132and a corresponding spring68,70. The spring68,70is inserted into an aperture131defined in the button body132. The spring68,70returns the button body132back to its initial position.

FIG. 20depicts an exploded view of a “valve manifold assembly/buttons/reversing arm” assembly134, according to one embodiment. The reversing lever arm46is pivotally coupled to the valve manifold48by a pin72inserted through a mounting hole136defined in the reversing lever arm46and through the mounting hole114defined in the body of the valve manifold48. The pin72locks the reversing lever arm46onto the valve manifold46. The irrigation and suction buttons28,30are inserted onto the valve manifold46. The springs68,70are aligned with the valve slots76,78to corresponding features. The irrigation and suction buttons28,30are operatively coupled to the corresponding irrigation and suction valves50,54by inserting the valve slots76,78to the corresponding protruding tabs124,126of the valves50,54.

FIG. 21depicts a perspective view of the assembled “valve manifold assembly/buttons/reversing arm” assembly134shown inFIG. 20, according to one embodiment.

FIG. 22depicts a perspective view of the right shroud16bportion of the handle assembly12of the electrosurgical device10shown inFIG. 1with the irrigation and suction hoses32,34threaded through a bottom portion thereof, according to one embodiment.

FIG. 23depicts a perspective view of the right shroud16bportion of the handle assembly12shown inFIG. 22with the “valve manifold assembly130/buttons28,30/reversing lever arm46” assembly134shown inFIG. 20-22in the process of being attached to the irrigation and suction hoses32,34, according to one embodiment.

FIG. 24depicts a side elevational view of the right shroud16bportion of the handle assembly12shown inFIG. 24with the “valve manifold assembly130/buttons28,30/reversing lever arm46” assembly134shown inFIG. 23attached to the irrigation and suction hoses32,34, according to one embodiment.

FIG. 25depicts a perspective view of the right shroud16bportion of the handle assembly12shown inFIG. 24with the “valve manifold assembly134/buttons28,30/reversing lever arm46” assembly134shown inFIG. 24attached to the irrigation and suction hoses32,34and an energy switch circuit board84, cable36, and retainer/electrical spring contact62mounted to the right shroud16b, according to one embodiment.

FIG. 26depicts a partial side elevational view of the right shroud16bportion of the handle assembly12shown inFIG. 25with the reversing lever arm46rotated forward in a maximum distal direction and the slide element40slidably attached over the nozzle, according to one embodiment. As previously discussed, the slide knob40is operatively coupled to the reversing lever arm46, which is operatively coupled to the trigger.

FIG. 27depicts a partial side elevational view of the right shroud16bportion of the handle assembly12shown inFIG. 26with the reversing lever arm46rotated backward in a maximum proximal direction to lock the slide element40in place, according to one embodiment.

FIG. 28depicts a perspective view of the right shroud16bportion of the handle assembly12shown inFIG. 27with the trigger20attached thereto and operatively coupled to the reversing lever arm46and the compression spring82, according to one embodiment. The trigger20is inserted in the right shroud16band the pin74is inserted through the mounting hole116. The trigger20lever arm body85is pivotally coupled to the right shroud16bby pin74at pivot point86. The compression spring82is compressed and inserted into the right shroud16band the tab88on the lever arm85.

FIG. 29depicts a partial perspective view of the right shroud16bportion of the handle assembly12shown inFIG. 28with the energy switch26and shaft unlock button42attached thereto, according to one embodiment.

FIG. 30depicts a perspective view of a left shroud portion16aof the handle assembly12shown inFIG. 29in the process of being attached to the right shroud16bportion of the handle assembly12, according to one embodiment.

FIG. 31depicts a perspective view of an assembled handle assembly12of the electrosurgical device shown inFIG. 1, according to one embodiment.

Embodiments with Tripper Coupled to Cam Arm, Gear Train, or Cables

In one embodiment, the electrosurgical device may include a trigger operatively coupled to cam arm(s), gear train, or cables to move the nozzle back and forth. A sliding base comprising a slide element would attach to the nozzle. A detent lock may be used to attach the slide element to the nozzle and the handle. The slide element may include features such as a cam surface or rack to couple to the trigger. Squeezing and releasing the trigger causes the slide element to move backward and forward thus pulling and pushing the nozzle backward and forward. In certain embodiments, the trigger may include multiple detent positions for fine stopping points. It may include a lock feature to keep the trigger in a closed position such that the nozzle stays in place, and it may have a spring to automatically return the trigger and nozzle to its starting position. Thus the trigger is easy to use in a pistol grip like handle configuration all the controls can be reached with one hand and enables quick and precise low force movement of the nozzle.

In one embodiment, an electrosurgical device comprises a sheath over a shaft that can extend over a monopolar electrode tip. The device may include a combination of RF monopolar suction and irrigation functions. The shaft may be a separate assembly that can be attached to a handle. The handle may contain a trigger coupled to a sliding feature to push the shaft forward and backward. The trigger may include a cam arm coupling to the sliding feature. The trigger may include a gear train to couple to the sliding feature. The trigger may include a cable system to couple to the sliding feature. The trigger also may include a locking feature to keep it closed in its second position. The locking feature can be a lever and spring on the trigger that automatically latches when closed. To unlock the trigger, the lever is pushed in the opposite direction from the latch. The lock also may be a close to lock then close again to unlock locking feature, which includes a spring biased member and a locking cam path. The trigger or handle may include spring biased feature(s) and detents to enable the trigger to lock in different positions. The trigger or the slide feature may include a spring coupled to them to return the trigger to its starting position automatically. In various embodiments, the electro-surgical device may employ RF energy to cauterize tissue in monopolar or bipolar energy modes. In various embodiments, the handle assembly may have a pistol grip configuration, a pencil grip configuration, or may be configured to articulate between a pistol grip and a pencil grip and vice-versa. These embodiments are described hereinbelow in connection withFIGS. 32-38.

FIG. 32depicts a transparent side elevational view of a handle assembly150of an electrosurgical device comprising a trigger152operatively coupled to a slide element154by way of a cam arm156where the trigger152is extended in the distal direction E and the slide element154is retracted in the proximal direction F, according to one embodiment. In various embodiments, the electro-surgical device may employ RF energy to cauterize tissue in monopolar or bipolar energy modes. In various embodiments, the handle assembly150may include a pistol grip configuration (as shown inFIGS. 32-34), a pencil grip configuration, or may be configured to articulate between a pistol grip and a pencil grip and vice-versa.

The trigger152is pivotally movable about pivot180. A return spring182returns the trigger152to its original position. In the configuration shown inFIG. 32, the trigger152is positioned distally and the cam arm156is positioned proximally. Thus, the trigger152attached to the cam arm156can move a nozzle174back and forth. The slide element154base attaches to the nozzle174. The slide element154base enables the nozzle174to be attached to the handle assembly150using a detent lock184(shown inFIG. 34). The slide element154base includes features such as a cam surface or rack to couple to the trigger152. Pulling the trigger152would slide the slide element154base forward and backward thus pushing and pulling the nozzle174forward and backward. In certain embodiments, the trigger152may include multiple detent positions for fine stopping points. The trigger152may include a lock feature to keep it closed so that the nozzle174stays in place the spring182automatically returns the trigger152and nozzle174to their starting position. Thus the trigger152is easy to use in a pistol grip like handle assembly150configuration all the controls can be reached with one hand and enables quick and precise low force movement of the nozzle174. The trigger152or the slide element154may be coupled to a spring182,186to return the trigger152and/or the slide element154back to its starting position automatically.

In one embodiment, an electrosurgical device comprises a shaft160that can extend over a monopolar electrode tip. The electrosurgical device may include a combination of RF monopolar suction and irrigation functions. The shaft160may be a separate assembly that can be attached to the handle assembly150.

The handle assembly150comprises a rotation knob158operatively coupled to the shaft160and the slide element154. Irrigation and suction buttons162,164are operatively coupled to corresponding irrigation and suction tubes166,168to control the flow of fluid and/or suction. The irrigation tube166and the suction tube168are fluidically coupled to a main flow channel174to deliver fluid to the surgical site or aspirate fluid and/or surgical matter from the surgical site by way of suction. The buttons162,164are electrically coupled to a circuit board176, which is coupled to a manifold assembly178comprising electrically controlled valves tat control the irrigation/suction functions of the electrosurgical device. An electrical button170or switch is electrically coupled to an electrical cable172and to an electrode tip located at the distal end of the shaft160such that activation of the electrical button170applies energy to an exposed electrode at the surgical site. As previously discussed in connection with the embodiments described in connection withFIGS. 1-31, the trigger152controls a slidable sheath that advances distally to conceal the electrode and retracts proximally to expose the electrode.

FIG. 33depicts a transparent side elevational view of the handle assembly150of an electrosurgical device shown inFIG. 32with the trigger152operatively coupled to the slide element154by way of the cam arm156where the trigger152is retracted in the proximal direction A and the slide element154is extended in the distal direction D, according to one embodiment. ComparingFIGS. 32 and 33, it can be seen that the slide element154advances a relative distance of “d2-d1” over the range of motion of the trigger152about the pivot180.

FIG. 34depicts a perspective transparent view of the handle assembly150of the electrosurgical device shown inFIG. 33with the trigger152operatively coupled to the slide element154by way of the cam arm156where the trigger is retracted in the proximal direction A and the slide element154is extended in the distal direction D with the rotation knob158removed to show the shaft detent locking element184, according to one embodiment. The detent locking element184can be employed to keep the trigger152closed in its second position, squeezed or triggered position. The trigger152or handle assembly150also may include spring biased feature(s) and detents to enable the trigger to lock in different positions. The trigger152locking element can be a lever and spring on the trigger152that automatically latches when closed. To unlock the trigger152, the lever is pushed in the opposite direction from the latch. The trigger locking element also may be a close to lock then close again to unlock locking feature, which includes a spring biased member and a locking cam path.

In various embodiments, the trigger152and slide element154may be operatively coupled to a gear train, cable pull system, or other force/torque amplification element or system, to reduce the force required to advance and retract the slide element154using the trigger152. The embodiment described below in connection withFIG. 35provides a handle assembly comprising a gear train operatively coupled to the trigger152and the slide element154and the embodiment described below in connection withFIG. 36provides a handle assembly comprising a cable pull system operatively coupled to the trigger152and the slide element154.

FIG. 35depicts a transparent side elevational view of a handle assembly190of an electrosurgical device comprising a trigger152operatively coupled to a slide element154by way of a gear train191attached to a rack198where the trigger152is extended in the distal direction and the slide element154is retracted in the proximal direction, according to one embodiment. As shown inFIG. 35, the gear train191is operatively coupled to the trigger152and the slide element154to push and pull the slide element154forward D (distal) and backward F (proximal). The gear train191comprises a first gear192that is rotatably movable about the pivot180. A second gear194is meshed with the first gear192and the second gear194is meshed with a third gear196that is meshed with a rack198. The rack198is coupled to the slide element154. As the trigger152is squeezed in direction A, the first gear191rotates about the pivot180in direction B and the second and third gears194,196rotate in direction C causing the rack198to move distally in direction D. As the trigger152is returned to its original position in direction E the gear train191reverses direction and moves the rack198proximally in direction F.

FIG. 36depicts a transparent side elevational view of a handle assembly200of an electrosurgical device comprising a trigger152operatively coupled to a slide element154by way of a cable pull system201where the trigger152is extended in the distal direction and the slide element154is retracted in the proximal direction, according to one embodiment. As shown inFIG. 36, the cable pull system201is operatively coupled to the trigger152and the slide element154to push and pull the slide element154forward D and backward F. The cable pull system201comprises a first pulley202that is rotatably movable about the pivot180. A second pulley204is coupled to the first pulley202by a first cable208. A third pulley206is coupled to the second pulley204by a second cable210. The third pulley206is coupled to a rack212, which is coupled to the slide element154. In various embodiments, the third pulley206may comprise a gear that with the rack212. As the trigger152is squeezed in direction A, the first pulley202rotates about the pivot180in direction B and the second and third pulleys204,206rotate in direction C causing the rack212to move distally in direction D. As the trigger152is returned to its original position in direction E, the cable pulley system201reverses direction and moves the rack212proximally in direction F.

FIG. 37depicts a perspective view of a shaft212portion of the hand assemblies150,190,200shown inFIGS. 32-36coupled to a rotatable knob158element that is coupled to a slide element154, according to one embodiment. The rotatable knob158is used to rotate the shaft clockwise and counterclockwise in directions G. The slide element154(FIGS. 32-36) moves the slidably movable sheath22forward (distally) D and backward (proximally) F by the various trigger152mechanisms described in connection withFIGS. 32-36. As previously discussed, the sheath22is advanced distally D when the trigger152(FIGS. 32-36) is moved distally in direction E to conceal the electrode24and the sheath22is retracted proximally F when the trigger152(FIGS. 32-36) is squeezed proximally in direction A to expose the electrode24.FIG. 38depicts a perspective view of the rotatable knob158element showing a shaft to slide element locking feature214and a nozzle174portion, according to one embodiment. With reference also toFIGS. 32-37, the locking feature214in the rotatable knob158locks the shaft160to the slide element154by way of the detent locking element184shown inFIG. 34.

Embodiments with Tube-Pinch Mechanism

In one embodiment, an electrosurgical device is provided that requires less force to press the irrigation and suction buttons. The device pinches irrigation and suction tubes to close off the flow of suction or water (fluid). In one embodiment, a cam roller is employed to pinch the irrigation and suction tubes shut. The cam roller rests on a cam arm that swings into the tube. As the cam arm swings into the tube it comes parallel to a pinch point on the opposite side of the tube. As the arm becomes parallel it pinches the tube shut. When parallel the arm takes very little force to pinch the tube. The suction and irrigation tubes take little force to pinch close for the first half of closing. Only when the tube is nearly fully shut does it take a lot of force to close. The cam arm takes advantage of this by increasing its mechanical advantage asymptotically the closer it gets to full close. This allows the cam arm to keep the tube pinched with a small spring. It also means the travel to rotate the roller arm off the tube is less. So this configuration uses the same amount of travel as a conventional device to activate the suction or irrigation buttons but with much less force. The electrosurgical device provides less force to fire the suction and irrigation buttons. The cam roller arrangement is compact and simple and requires a smaller spring for easier assembly. These embodiments are described hereinbelow in connection withFIGS. 39-42.

In one embodiment, an electrosurgical device comprises a combination RF monopole, suction, and irrigation device with a tube pinching mechanism comprising a button, cam arm, roller, and spring. In various embodiments, the electro-surgical device may employ RF energy to cauterize tissue in monopolar or bipolar energy modes. In various embodiments, the handle assembly may have a pistol grip configuration, a pencil grip configuration, or may be configured to articulate between a pistol grip and a pencil grip and vice-versa.

FIG. 39depicts a transparent side elevational view of a handle assembly220of an electrosurgical device comprising a tube pinching mechanism222to engage with a tube224to deactivate fluid flow or suction, according to one embodiment.FIG. 41depicts a transparent perspective view of the handle assembly220shown inFIG. 39. With reference now toFIGS. 39 and 41, the tube pinching mechanism222is engaged with the tube224to cut off flow. The tube pinching mechanism222comprises a cam arm226with a slot244defined therein. On one end, the cam arm226is pivotally movable about a pivot248and comprises a roller228on an opposite end. The tube224is positioned between the roller228and a wall250of the handle assembly220. As the roller228moves counterclockwise it pinches the tube224against the wall250to block flow through the tube224. A button238comprising an arm256is used to disengage the roller228and open up the flow channel in the tube224as shown inFIGS. 40 and 42.

InFIGS. 39 and 41, the button238is pushed out by a spring232force. A projecting tab246is coupled to one end of the arm256. The tab246is confined to move within the slot244to cause the cam arm226to rotatably move about the pivot248. The arm256also is coupled to a spring232which is normally in compression. The spring232force holds the button238in the outward configuration shown inFIGS. 39 and 41. Thus, when the button238is not actuated or pressed, the spring232force acts on the arm238which rotates about a pivot240causes the cam arm226to rotate counterclockwise until the roller246pinches the tube224against the wall250at the pinch point230. The spring232force can be selected to accommodate the amount of pinch force that is applied to the tube224. To release the pinch point230and cause fluid to flow within the tube224, the button238is pressed as sown inFIGS. 40 and 42.

FIG. 40depicts a detailed transparent side elevational view of the handle assembly220shown inFIGS. 39 and 41with the tube pinching mechanism222disengaged with the tube224to activate fluid flow or suction, according to one embodiment.FIG. 42depicts a transparent perspective view of the handle assembly shown inFIG. 40with the tube pinching mechanism disengaged with the tube to activate fluid flow or suction, according to one embodiment. As shown inFIGS. 40 and 42, when the button238is pressed as indicated by arrow I, the arm256rotates counterclockwise about the pivot240causing the projecting tab246to engage and slide along the slot244within the cam arm226and applies a downwardly force. The downwardly force applied by the projecting tab246on the cam arm226slot244causes the cam arm226to rotate clockwise and accordingly moves the roller224away from the pinch point230and thus releases the pinch force applied to the tube224. The rotation of the arm256further compresses the spring232in direction H. Accordingly, when the button is released, the spring232returns the button238to its original position as shown inFIGS. 39 and 41causing the cam arm226to rotate counterclockwise and causing the roller28to pinch the tube224against the wall250at the pinch point230.

With reference toFIGS. 39-42, the handle assembly220further comprises irrigation and suction buttons234,236electrically coupled to circuit board254. The irrigation and suction buttons234,236are actuated to control the flow and suction through the tube224with reduced force.

Embodiments with Articulatable Handle Assembly

In one embodiment, an electrosurgical instrument comprises energy (monopolar or bipolar), suction, and irrigation functions in a device that can be configured either in a pencil or a pistol handle assembly configuration. This expands how the operator (e.g., surgeon) can use the device to access the patient (side versus top). The device can be easily transformed from the pencil to the pistol configuration and vice-versa to provide the operator more options and to stock fewer products on the shelf.

In one embodiment, the electrosurgical device comprises a rotating sealed suction and irrigation chamber with a locking mechanism. The handle assembly may include two components such that it can bend around a pivot. A lock prevents the handle from pivoting until desired. The rotational suction and irrigation chamber or manifold allows the device to transform from straight to bent and vice-versa. The manifold employs an O-ring to keep the joint sealed when articulated. The articulatable device enables a surgeon to utilize the device in two-different modes for better handling in different orientations. Rotating sealed manifold removes the issue of pinch tubing and reduces the force to transform the device.

In one embodiment, an electrosurgical device comprises energy (e.g., monopolar or bipolar), irrigation, and suction functions in one combination device that includes a two-part body that can bend and lock into pencil (straight) and pistol (bent) positions. An energy, irrigation, and suction combination device includes a rotational suction and irrigation chamber to allow the body to bend. These embodiments are described hereinbelow in connection withFIGS. 43-74.

FIG. 43depicts a side elevational view of a handle assembly300of an electrosurgical device comprising an articulating sealed fluid flow manifold assembly302with a locking mechanism positioned in a straight/non-rotated (pencil) configuration, according to one embodiment.FIG. 44depicts a side elevational view of the handle assembly300shown inFIG. 43arranged in a bent/rotated (pistol) configuration, according to one embodiment.FIG. 45depicts a perspective view of the handle assembly shown inFIGS. 43-44arranged in a straight non-rotated (pencil) configuration, according to one embodiment.FIG. 46depicts an exploded view of the handle assembly300shown inFIGS. 43-45, according to one embodiment.

With reference now toFIGS. 43-46, in one embodiment the handle assembly300comprises a proximal portion304and a distal portion306. The articulating sealed fluid flow manifold assembly302comprises a proximal articulating end302aand a distal articulating end302b. The proximal portion306comprises a right shroud304aand a left shroud304b. The distal portion306comprises a right shroud306aand a left shroud306b. The proximal portion304and the distal portion306of the handle assembly300including the proximal and distal articulating ends302a,302bof the manifold assembly302articulate at articulation joint308. A locking element322enables the handle assembly300to be locked in a predetermined position. The locking element322cooperates with an articulation lock350and spring352.

The proximal articulating end302aof the articulating sealed fluid flow manifold302comprises an irrigation port315and a suction port316. An irrigation tube310, suction tube312, and an electrical cable314are received at a bottom portion of the proximal handle portion304. The irrigation tube310is fluidically coupled to irrigation port315and the suction tube312is fluidically coupled to the suction port316. An irrigation button318controls the irrigation flow through the irrigation flow path and a suction button320controls the suction flow through the suction path. The articulating sealed fluid flow manifold302comprises a valve manifold332comprising valve apertures360,362configured to rotatably receive an irrigation valve336and a suction valve338therein. The irrigation valve336comprises a projecting tab364configured to engage a slot368formed on a linear arm portion of the irrigation button318. The slot368acts on the projecting tab364to rotate the irrigation valve336port372to regulate the flow through the irrigation flow path. The suction valve338comprises a projecting tab366configured to engage a slot370formed on a linear arm portion of the suction button320. The slot370acts on the projecting tab366to rotate the suction valve338port374to regulate the flow through the suction flow path. Springs342,344are inserted into the irrigation and suction buttons318,320to return them to their original position. An articulating output manifold348is fluidically and rotatably coupled to a main flow port334defined by the valve manifold332. O-ring seal354seals the main flow port375of the articulating output manifold348. A washer356is located over the O-ring354and attached to the main flow port375of the articulating output manifold348. The retainer/electrical contact spring358is placed over the washer356.

A rotatable knob324is provided on the distal portion306of the handle assembly300to manually control the rotation of a shaft326. Energy buttons328,330are located on the proximal portion304of the handle assembly300. The energy buttons328,330are electrically coupled to a circuit board340, which electrically coupled to the electrical cable314. The electrical cable314is electrically coupled to an energy source. The circuit board also is electrically coupled to a retainer/electrical spring contact358, which is electrically coupled to the distal electrode. The energy buttons328,330are utilized to energize the distal electrode through the retainer/electrical spring contact358, as discussed throughout this disclosure.

FIGS. 47A-Ddepict a sequence of steps for rotating and locking the handle assembly300shown inFIGS. 43-46, according to one embodiment. InFIG. 47Athe proximal and distal handle portions304,306of the handle assembly300are in a locked position. The articulating joint308comprises a detent element comprising a plurality of detents309that engage a slot311formed in the spring352loaded articulation lock350. To rotate the proximal handle portion304, the spring352loaded articulation lock350is pulled in the direction indicated by arrow J inFIG. 47Bto disengage the slot311of the detent element from the detent309and allowing the proximal handle portion304to rotate in the direction indicated by arrow K as shown inFIG. 47C. Once the proximal handle portion304is in the desired position, the spring352loaded articulation lock350is released allowing it to engage with another detent309to lock the handle assembly300in place.

FIG. 48depicts a partial sectional view of the handle assembly300shown inFIGS. 43-46arranged in a flow blocked straight non-rotated (pencil) configuration, according to one embodiment. The irrigation and suction buttons318,320are in a flow blocked arrangement as indicated by the outward positions of both buttons318,320. The springs342,344bias the buttons outwardly to maintain the valves336,338in a closed orientation. The slots368,370in the arms of the buttons318,320engage the projecting tabs364,366to control the rotation of the valves336,338.

FIG. 49depicts a partial sectional view of the handle assembly300shown inFIGS. 43-46arranged in a flow opened straight non-rotated (pencil) configuration, according to one embodiment. As shown, both the irrigation button318and the suction button320are depressed and the valves336,338are rotated to an open flow position by the slots368,370acting on the projecting tabs364,366. The buttons318,320travel over a predetermined distance. In one embodiment, the buttons318,320travel over a predetermined distance of about 0.155 inches.

FIG. 50depicts a partial sectional view of the handle assembly300shown inFIGS. 43-46arranged in a flow blocked bent rotated (pistol) configuration, according to one embodiment. The proximal handle portion304is rotated about the articulation joint308. The irrigation and suction buttons318,320are now biased by the springs342,344in an outward position to close the flow valves336,338.

FIG. 51depicts an exploded view of the articulating sealed fluid flow manifold assembly302for the handle assembly300shown inFIGS. 43-46showing the flow paths, stop cock valves336,338, and O-ring346seal between articulating manifold ends, according to one embodiment.FIG. 52depicts a perspective sectional view of the articulating sealed fluid flow manifold assembly302for the handle assembly300shown inFIGS. 43-46showing the stop cock valves336,338in a closed position to stop the fluid flow in the flow channels378,380of the valve manifold332, according to one embodiment.FIG. 53depicts a sectional view of the articulating sealed fluid flow manifold assembly302for the handle assembly300shown inFIGS. 43-46showing one of the flow paths382before the closed stop clock valve336, according to one embodiment. In the example illustrated inFIG. 53, the flow path382is a suction flow path.

With reference now toFIGS. 51-53, the articulating output manifold348is sealed to the main flow port334of the valve manifold332by O-ring346. The irrigation and suction valves336,338are inserted into corresponding apertures360,362formed in the valve manifold332. Irrigation and suction ports315,316fluidically couple to corresponding flow channels378,380within the valve manifold332. Both flow channels378,380combine at the main flow port334, which is coupled to the nozzle376for delivering and suctioning fluid from the surgical site through the shaft326.

FIG. 54depicts a sectional view of the articulating sealed fluid flow manifold assembly302for the handle assembly300shown inFIGS. 43-46showing an electrical wire path384, according to one embodiment.FIG. 55depicts a sectional view of the articulating sealed fluid flow manifold assembly302for the handle assembly300shown inFIG. 54arranged in a straight non-rotated (pencil) configuration showing an electrical wire path384arranged, according to one embodiment.FIG. 56depicts a sectional view of the articulating sealed fluid flow manifold assembly302for the handle assembly300shown inFIG. 54arranged in a bent rotated (pistol) configuration showing an electrical wire path384, according to one embodiment.

With reference now toFIGS. 54-56, the wire path384includes multiple electrical conductors. In the illustrated embodiment, the wire path384includes three electrical conductors384a-384c. The electrical cable314is received at one end of the right shroud304aand the three individual electrical conductors384a,384b,384care electrically coupled to the circuit board340to couple to the energy source (not shown). An additional electrical conductor384dis coupled between the circuit board340to the retainer/electrical contact spring358which is electrically coupled to the electrode at the distal end of the shaft.

FIGS. 57-58depict the irrigation and suction buttons318,320layout relative to the rotatable knob300for the hand assembly300shown inFIGS. 43-46.FIG. 57depicts a side elevational view of the handle assembly300shown inFIGS. 43-46arranged in a bent rotated (pistol) configuration showing the distance “d3” between the distal button318and the distal rotatable knob324, according to one embodiment.FIG. 58is a perspective view of the handle assembly300shown inFIG. 57arranged in a bent rotated (pistol) configuration showing the relative distance between the distal button318and the rotatable knob324, according to one embodiment.FIG. 59depicts a side elevational view of the handle assembly300shown inFIGS. 43-46arranged in a straight non-rotated (pencil) configuration showing the distance “d4” between a distal button318and the rotatable knob324, according to one embodiment. In various embodiments, the distances “d3” and “d4” can be selected such that the handle assembly300can be operated with one hand. In one embodiment, the distance “d3” is about 1.85 inches and the distance “d4” is about 1.20 inches.

FIGS. 60-74depict processes for assembling the handle assembly300. InFIG. 60the irrigation and suction tubing310,312are attached to flow components and inFIGS. 61-62a seal is inserted at the main flow port375of the articulating output manifold348. InFIGS. 63-66the articulating output manifold348is assembled to the valve manifold332. InFIGS. 67-68the articulation lock350and spring352is inserted into the articulation joint308of the right shroud304a,306aportion of the handle assembly300. InFIG. 69, the manifold assembly shown inFIG. 66is inserted into the right shroud304a,306aportion of the handle assembly300. InFIG. 70the unlock arm322is inserted. InFIG. 71the distal left shroud306bis inserted. InFIG. 72the proximal left shroud304bis inserted. InFIG. 73the energy buttons328,330are inserted, and inFIG. 74the complete assembled handle assembly300is shown. The assembly processes are now described in more detail.

FIG. 60depict a process for assembling the irrigation and suction tubing310,312andFIGS. 61-62depict a process for assembling a seal to the main flow port375of the articulating output manifold348.FIG. 60depicts a process for assembling the irrigation and suction tubes310,312to flow connection components of the manifold subassembly302for the handle assembly300shown inFIGS. 43-46, according to one embodiment. The irrigation tube310is assembled to flow connection components such as an irrigation Luer386and irrigation clamp388. The suction tube312is assembled to a suction coupling390and suction adapter392.FIG. 61depicts a process for assembling the O-ring354and washer356seal to the main flow port375of the articulating output manifold348of the handle assembly300shown inFIGS. 43-46, according to one embodiment. The O-ring354is inserted into the main flow port375and then the washer356is ultrasonically welded to the output manifold348.FIG. 62depicts a perspective view of the assembled articulating output manifold348of the handle assembly300shown inFIG. 61, according to one embodiment.

FIGS. 63-66illustrate a process for assembling the articulating sealed fluid flow manifold assembly302portion of the handle assembly300shown inFIGS. 43-46.FIG. 63depicts an exploded view of the manifold subassembly302comprising a valve manifold332and an output manifold348. The O-ring346is inserted over an edge394of the valve manifold332about the main flow port334and the output manifold348is placed over the main flow port334of the valve manifold332. The manifold assembly302articulates where the output manifold348and the valve manifold332components are rotatably connected. Then, the irrigation and suction valves336,338are inserted into the corresponding apertures360,362formed in the body of the valve manifold332.FIG. 64depicts a perspective view of the assembled manifold subassembly302shown inFIG. 63, according to one embodiment.FIG. 65depicts a perspective view of the assembled manifold subassembly302shown inFIG. 64with irrigation and suction buttons318,320and corresponding springs342,344inserted in corresponding slots396,398formed on the valve manifold332body, according to one embodiment.FIG. 66depicts a perspective view of the manifold subassembly302with irrigation and suction buttons318,320and corresponding springs342,344coupled thereto as shown inFIG. 65with the circuit board340and contact spring358attached thereto, according to one embodiment.

FIG. 67depicts the articulation lock250and spring352inserted at the articulation joint308of the proximal right shroud304aportion of the handle assembly300shown inFIGS. 43-46with, according to one embodiment.

FIG. 68depicts the distal right shroud306aportion of the handle assembly300shown inFIGS. 43-46coupled to the proximal right shroud304aportion of the handle assembly300shown inFIG. 67, according to one embodiment.

FIG. 69depicts the valve manifold assembly302shown inFIG. 66inserted into the right shroud304a,306aportion of the handle assembly300shown inFIG. 68, according to one embodiment.

FIG. 70depicts the unlock arm322inserted into the distal right shroud306aportion of the handle assembly300shown inFIG. 69, according to one embodiment.

FIG. 71depicts the distal left shroud306binserted over the distal right shroud306aportion of the handle assembly300shown inFIG. 70, according to one embodiment.

FIG. 72depicts the proximal left shroud304bportion of the handle assembly300inserted over the handle assembly300shown inFIG. 71, according to one embodiment.

FIG. 73depicts an exploded view of the handle assembly300shown inFIG. 72and energy buttons328,330, according to one embodiment.

FIG. 74depicts a complete handle assembly300of the electrosurgical device, according to one embodiment.

Embodiments with Tripper Lockout

FIG. 75depicts a perspective view of a handle assembly400with a trigger locking mechanism, according to one embodiment, the handle assembly being compatible with the electrosurgical device shown inFIG. 1, according to one embodiment. The handle assembly400comprises a trigger420having a trigger lock cam411formed therein to engage an element of a slidable lockout button401. In other aspects, the handle assembly400includes functional elements similar in structure and operation as the handle assembly12described herein with reference toFIGS. 1-31. The features of the handle assembly400that are structurally and functionally similar to the handle assembly12depicted inFIGS. 1-31may not be described in the same level of detail for conciseness and clarity of disclosure and, therefore, should not be considered a disclaimer or limitation.

Accordingly, turning now briefly toFIG. 75, the handle assembly400comprising a trigger lockout mechanism is compatible with the electrosurgical device10shown inFIG. 1, according to one embodiment. The shaft knob of the handle assembly400is extended distally along a slide element440, which encases a nozzle444fluidically coupled to a manifold located within the handle assembly400. As will be described in more detail below, the slide element440element is operatively coupled to the trigger420. The trigger420is shown extended in a first “initial” position (e.g., extended distally in direction E) under the influence of a biasing element such as a spring. The position of the trigger420shown inFIG. 75may be referred to herein as the initial or original position in which the trigger420is normally configured in and may automatically return to unless a trigger locking mechanism is provided to prevent automatic return to the initial position. The trigger420includes a trigger lock cam411which cooperates with a pin portion of the trigger lock mechanism. A slidable lockout button401is used to disable the lockout.

The handle assembly400is configured as a pistol grip and comprises left and right handle housings or shrouds416a,416b(FIG. 76), a rotatable shaft knob (not shown here), a trigger420, an energy button426or switch, a first flow control button, e.g., an irrigation button428, and a second flow control button, e.g., a suction button430. Irrigation and suction tubes432(FIG. 76),434and an electrical cable436enter the handle assembly400through a bottom portion. The shaft portion comprises a slidable sheath that extends distally and retracts proximally to respectively conceal and expose the electrode portion. The slidable sheath is operatively coupled to the trigger420. The irrigation and suction tubes432,434are fluidically coupled to a manifold and respective valves located within the space created between the left and right housing portions416a,416bof the handle assembly400. The irrigation and suction buttons428,430control stopcock valves located within the manifold to control the flow of irrigation fluid through the irrigation tube432and suction through the suction tube434. The electrical cable436is electrically coupled to the energy switch426and an energy source8(FIG. 1). The energy source8may be a monopolar or bipolar RF energy source. The energy source8may be suitable for therapeutic tissue treatment as well as tissue cauterization/sealing. The energy switch26controls the delivery of energy to the electrode. A detailed explanation of each of these control elements is provided hereinbelow. As used throughout this disclosure, a button refers to a switch mechanism for controlling some aspect of a machine or a process. The buttons may be made out of a hard material such as usually plastic or metal. The surface may be formed or shaped to accommodate the human finger or hand, so as to be easily depressed or pushed. Buttons can be most often biased switches, though even many un-biased buttons (due to their physical nature) require a spring to return to their un-pushed state. Terms for the “pushing” of the button, may include press, depress, mash, and punch.

FIG. 76depicts an exploded view of the handle assembly400of the electrosurgical device10shown inFIG. 1, according to one embodiment. This view shows the components of the valve manifold located within the handle assembly400as well as the elements of a trigger lockout mechanism409. The trigger lockout mechanism409comprises a housing404which supports the slidable lockout button401, a first and second spring406,407, a plunger405, and a pin408. The left and right shrouds416a,416b(handle housings) provide a support for the irrigation and suction fluid flow control buttons428,430, the trigger420, the slide element440, and the trigger lockout mechanism409. In addition, the left and right shrouds416a,416balso support a valve manifold448that is fluidically coupled to the irrigation and suction ports432,434as well as the nozzle444. The left and right shrouds416a,416balso support the energy switch426and a circuit board element84as well as the electrical cable436.

In one embodiment, the valve manifold48is configured to rotatably support an irrigation valve450and a suction valve454. Although the irrigation and suction valves450,454are stopcock valves, other suitable valves may be employed without departing from the scope of the present disclosure. Irrigation valve O-rings452are located about grooves provided on the outer surface of the irrigation valve450. Suction valve O-rings456are located about grooves provided on the outer surface of the suction valve454. The irrigation and suction valves450,454include tabs or drive dogs that engage respective slots76,78formed on linear arm portions of the respective irrigation and suction buttons428,430. The valve manifold448also includes an O-ring458and a washer460. A retainer clip462that also acts as an electrical spring contact retains the valve manifold48to the right shroud416b. Irrigation and suction ports are used to fluidically couple the valve manifold448to the irrigation tube432and suction hose480, which is fluidically coupled to the suction tube coupling434. The valve manifold48is supported within the handle assembly400by a pin474which is received within corresponding holes formed in each shroud416a,416b.

The irrigation and suction buttons428,430(flow control buttons) each include a spring468,470to bias and return the buttons428,430to the distal position after being actuated.

A reversing lever arm446is pivotally coupled to the left and right shrouds416a,416bvia a pin472. A first projecting tab is received within a corresponding hole in the right shroud416b. The lever arm485includes a pivot hole about which the trigger420rotates. The reversing lever arm446is operatively coupled to the slide knob440, which is operatively coupled to a slidable sheath22(FIGS. 1,3,5,7) of a shaft portion14(FIGS. 1,3,5,7). The notch portion of the lever arm485of the trigger420engages a projecting tab of the reversing lever arm446to cause the motion of the slide knob440to match the motion of the trigger420, e.g., trigger420forward—slide knob440forward and trigger420backward—slide knob440backward. The slide knob440is slidably movable over the nozzle444, which is fluidically coupled to the output port of the valve manifold448. A torsion spring482is located over a hub490formed in the right shroud416b. One arm of the torsion spring482is coupled to a slot488formed in the lever arm485portion of the trigger420and another arm of the torsion spring482is located against a back wall of the right shroud416bto bias the trigger420outwardly in a distal position when not squeezed and to return the trigger420outwardly to the distal position when the operator releases the trigger420.

The circuit board484is mounted to the right shroud416b. The energy switch426is electrically coupled to the circuit board484. The electrical spring contact462also is electrically coupled to the circuit board484. The electrical spring contact462is electrically coupled to the electrode24(FIGS. 1,3,5). The electrical cable436couples energy from the energy source to the circuit board484. When the energy switch426is activated energy is coupled from the energy source to the electrode24via the electrical spring contact462.

FIG. 77depicts a partial transparent side elevational view of the handle assembly400shown inFIG. 75with a trigger420portion in a second position and a slidably movable element440in a retracted position, according to one embodiment. In order to prevent the trigger420from locking once squeezed in direction A, the slidable lockout button401is slid forward, to enable trigger420to be squeezed in direction A without engaging the trigger lockout mechanism. When the trigger420is back, as shown, the shaft is back in direction F. This position allows energy to be applied to the tip.

FIG. 78depicts a partial transparent side elevational view of the handle assembly400shown inFIG. 75with the trigger420portion in a first position and the slidably movable element440is in an extended position, according to one embodiment. Also shown is the trigger lock cam411, which engages the pin portion of the trigger lockout mechanism409. The trigger420is sprung forward in direction E to enter the suction and irrigation mode(s). The nozzle444moves distally in direction D over the electrode tip. The flow control buttons428,430are shown pressed.

FIG. 79depicts a partial transparent side elevational view of the handle assembly400shown inFIG. 75with the trigger420portion in a second position and the shaft in a retracted position and fluid flow control buttons, e.g.,428,430, pushed out to disable fluid flow, according to one embodiment. The trigger420is shown in a locked position where a distal portion of the slidable element401engages a notch portion of the plunger405.

FIG. 80depicts a partial transparent side elevational view of the handle assembly400shown inFIG. 75with the trigger420portion in a first position and the shaft in an extended position and the fluid flow control buttons428,430pushed in to rotate the flow valves450,454and enable fluid flow, e.g., irrigation and suction, according to one embodiment. The trigger420includes a trigger lock cam411.

FIG. 81depicts a partial cut-away transparent side elevational view of the handle assembly400shown inFIG. 75with the reversing arm446operatively coupled to the trigger420where the trigger420is located in a forward (distal) position as biased by a torsion spring482to extend the slide element440forward in a distal direction to conceal the electrode, according to one embodiment.

FIG. 82depicts a partial cut-away transparent side elevational view of the handle assembly400shown inFIG. 75with the trigger420in a backward (proximal) position squeezed to overcome the bias force of the torsion spring482to retract the slide element440backward in a proximal direction to expose the electrode, according to one embodiment. The torsion spring482returns the trigger420to its initial location unless the trigger lockout mechanism409is engaged to lock the trigger, according to one embodiment.

FIG. 83depicts a partial cut-away transparent side elevational view of the handle assembly400shown inFIG. 75with a wire cover402, according to one embodiment. The wire cover402covers the wires4108,4109along an internal wire path to prevent the trigger420from hitting the wires4108,4109during operation.

FIG. 84depicts a partial perspective view of the handle assembly400shown inFIG. 75showing the trigger420and reverse arm446elements, according to one embodiment. This view also shows the trigger lock cam411which comprises a channel415formed around a wall413. The pin408portion (FIG. 2) of the trigger lockout mechanism409(FIG. 2) is slidable within the channel415as guided by the wall413to lockout the trigger420after it has been squeezed.

FIG. 85depicts a perspective view of the trigger420and the trigger plate403elements of the handle assembly400shown inFIG. 75, according to one embodiment. The trigger plate403engages the reverse arm446to enable the trigger420motion to match the slidable element440motion, e.g., trigger forward—knob forward and trigger back—knob back.

FIG. 86depicts a perspective view of the trigger lockout assembly409for the handle assembly400shown inFIG. 75, according to one embodiment. The slidable lockout button401is located within the housing404(box) along with springs406,407, and the plunger405. The pin408is inserted through an aperture formed through the body of the plunger405. The pin408engages the trigger lock cam411channel415formed around the wall413.

FIG. 87depicts perspective view of an interior portion of the left shroud416aof the handle assembly shown inFIG. 75showing the trigger lockout assembly409located therein, according to one embodiment.

FIG. 88depicts a perspective view of a housing404portion of the trigger lockout assembly409shown inFIG. 86, according to one embodiment. The housing404portion of the trigger lockout assembly409is positioned within the left shroud416asuch that the pin408engages the trigger lock cam411when the trigger420is squeezed.

FIG. 89depicts a perspective view of the trigger lockout assembly409shown inFIG. 86, according to embodiment. As shown inFIG. 89, with the slidable lockout button401in a first position enables the plunger405to move within the spring aperture to enable the pin408to engage the trigger lock cam411and lockout the trigger420once it has been squeezed, as shown inFIG. 90, where the arrows represent the path of the pin408moving through the channel415of the trigger lock cam411. To lock the trigger420, the pin rests in a recess427(shown inFIG. 91). When the pin408rests in the notch417, the trigger420is locked out. Squeezing the trigger420again, however, forces the pin408to continue following the contour of the wall413to release or unlock the trigger420as shown by the arrows.

FIG. 91depicts the trigger lockout assembly409shown inFIG. 86being bypassed by sliding the slidable lockout button401, according to one embodiment. As shown by the arrows, sliding the slidable lockout button401forward forces the pin408down out of the trigger lock cam411channel415(path) such that the pin408does not locate in the notch417to lockout the trigger420.

Other Example Features

While the examples herein are described mainly in the context of electrosurgical instruments, it should be understood that the teachings herein may be readily applied to a variety of other types of medical instruments. By way of example only, the teachings herein may be readily applied to tissue graspers, tissue retrieval pouch deploying instruments, surgical staplers, ultrasonic surgical instruments, etc. It should also be understood that the teachings herein may be readily applied to any of the instruments described in any of the references cited herein, such that the teachings herein may be readily combined with the teachings of any of the references cited herein in numerous ways. Other types of instruments into which the teachings herein may be incorporated will be apparent to those of ordinary skill in the art.

The disclosed embodiments have application in conventional endoscopic and open surgical instrumentation as well as application in robotic-assisted surgery.

It is worthy to note that any reference to “one aspect,” “an aspect,” “one embodiment,” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the aspect is included in at least one aspect. Thus, appearances of the phrases “in one aspect,” “in an aspect,” “in one embodiment,” or “in an embodiment” in various places throughout the specification are not necessarily all referring to the same aspect. Furthermore, the particular features, structures or

In summary, numerous benefits have been described which result from employing the concepts described herein. The foregoing description of the one or more embodiments has been presented for purposes of illustration and description. It is not intended to be exhaustive or limiting to the precise form disclosed. Modifications or variations are possible in light of the above teachings. The one or more embodiments were chosen and described in order to illustrate principles and practical application to thereby enable one of ordinary skill in the art to utilize the various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the claims submitted herewith define the overall scope.

1. An electrosurgical device, comprising: a handle assembly comprising: a valve having an input port and an output port, the input port fluidically coupled to either an irrigation source or a suction source; at least one button operatively coupled to the valve to control flow through the valve; at least one switch to electrically couple energy from an energy source; and a trigger; a shaft comprising: a slidable element operatively coupled to the trigger; and an electrode electrically coupled to the switch; wherein the trigger is operable to position the slidable element relative to the electrode to conceal or expose the electrode.

2. The electrosurgical device of clause 1, comprising a nozzle fluidically coupled to the output port of the valve, wherein the slidable element is fluidically coupled to the nozzle.

3. The electrosurgical device of clause 1, wherein the slidable element comprises a sheath fluidically coupled to the output port of the valve.

4. The electrosurgical device of clause 1, comprising a lever operatively coupled to the trigger and the slidable element such that the motion of the trigger is correlated to the motion of the slidable element.

5. The electrosurgical device of clause 4, wherein the slidable element is retracted in a proximal direction when the trigger is actuated in a proximal direction; and wherein the slidable element is advanced in a distal direction when the trigger is actuated in a distal direction.

6. The electrosurgical device of clause 1, comprising a cam operatively coupled to the trigger and the slidable element such that the motion of the trigger is correlated to the motion of the slidable element.

7. The electrosurgical device of clause 1, comprising a gear assembly operatively coupled to the trigger and the slidable element such that the motion of the trigger is correlated to the motion of the slidable element.

8. The electrosurgical device of clause 1, comprising a cable pull system operatively coupled to the trigger and the slidable element such that the motion of the trigger is correlated to the motion of the slidable element.

9. The electrosurgical device of clause 1, comprising a spring operatively coupled to the trigger to return the trigger to its un-triggered state.

10. The electrosurgical device of clause 1, comprising a valve manifold to contain the valve.

11. The electrosurgical device of clause 1, wherein the button comprises a linear arm portion defining a slot and the valve comprises a projecting tab operatively coupled to the slot, wherein liner motion of the button arm translates into rotation of the valve.

12. The electrosurgical device of clause 1, wherein the valve is a stopcock valve.

13. The electrosurgical device of clause 1, comprising a locking mechanism operatively coupled to the trigger.

14. The electrosurgical device of clause 13, wherein the locking mechanism comprises a plurality of detents to lock the trigger at a plurality of positions.

15. The electrosurgical device of clause 13, wherein the trigger is movable from a first position to a second position and the locking mechanism maintains the trigger locked in the second position.

16. The electrosurgical device of clause 13, wherein the locking mechanism comprises a lever and a spring located on the trigger that automatically latches when the trigger is closed.

17. The electrosurgical device of clause 16, wherein the lever is pushed in an opposite direction from the latching direction to unlock the trigger.

18. The electrosurgical device of clause 16, comprising a spring biased member and a locking cam operatively coupled to the trigger, wherein the locking mechanism locks the trigger when the trigger moved in a first direction and unlocks the trigger when the trigger is moved again in the closed direction.

19. The electrosurgical device of clause 1, wherein the slide element is operatively coupled to a spring to return the slide mechanism to its starting position automatically.

20. An electrosurgical device, comprising: a handle assembly defining a rigid wall; a cam arm supported by the handle assembly and pivotally movable about a first pivot on one side and comprising a roller supported on another side, the cam arm defining a slot therebetween; a first button supported by the handle assembly and pivotally movable about a second pivot, the first button comprising: an arm; and a projecting tab slidably engaged with the slot; a second button pivotally coupled to the cam arm at the first pivot; and a bias element acting on the arm of the first button to force the cam arm to pivotally move in a first direction and the roller to move toward the rigid wall of the handle assembly; wherein pressing the first button overcomes the force of the bias element and the projecting tab applies a force on the slot to pivotally move the cam arm in a second direction and to move the roller away from the rigid wall of the handle assembly.

21. The electrosurgical device of clause 20, comprising a flexible tube located between the rigid wall and the roller such that the roller applies a pinching force against the tube when the cam arm is pivotally forced in the first direction by the bias element.

22. The electrosurgical device of clause 21, wherein the pinching force against the tube is removed when the cam arm is pivotally moved in the second direction.

23. The electrosurgical device of clause 20, wherein the second button is operable to partially control the force applied to the cam arm.

24. An electrosurgical device comprising: a handle assembly comprising an articulating handle comprising a proximal housing and a distal housing rotatably coupled at an articulation joint; a sealed fluid flow manifold assembly configured to articulate about the articulation joint; and a locking mechanism positioned at the articulation joint to lock the proximal housing and the distal hosing in a configuration.

25. The electrosurgical device of clause 24, wherein the articulating fluid flow manifold assembly comprises: a valve manifold defining at least one flow path; and an output manifold rotatably coupled to the valve manifold at the articulation joint and sealed to the valve manifold.

26. The electrosurgical device of clause 25, wherein the valve manifold comprises: a first port fluidically coupled to a first flow path; a second port fluidically coupled to a second flow path; a third port fluidically coupled to third flow path and to the first and the second flow paths, the third port fluidically coupled to the output manifold.

27. The electrosurgical device of clause 25, wherein the at least one flow path comprises at least one valve rotatably movable within the valve manifold and operatively coupled to at least one button supported by handle assembly.

28. The electrosurgical device of clause 27, wherein the at least one button comprises an arm portion defining a slot to engage a projecting tab on the at least one valve; and wherein linear motion of the arm portion translates to rotational motion of the valve to control flow through the valve.

29. The electrosurgical device of clause 24, wherein the locking mechanism comprises and articulation lock and spring, where in the articulation lock comprises a slot configured to engage a plurality of detents formed on the articulation joint and the spring biases the slot against detent to lock the articulation joint.