Battery-powered surgical devices including internally-mounted visual indicators

An assembly for use with a surgical device includes an enclosure defining a passageway extending from an interior to an exterior thereof and a visual indicator mounted within the interior of the enclosure adjacent the passageway. The visual indicator is configured to emit light. The passageway is partially defined by a concave surface of the enclosure and/or a chamfered portion of the enclosure to facilitate the passage of light emitted by the visual indicator through the passageway and to the exterior of the enclosure to increase the external viewing angle of the light emitted from the visual indicator.

BACKGROUND

1. Technical Field

The present disclosure relates to battery-powered devices, and, more particularly, to battery-powered devices including internally mounted visual indicators, e.g., LED's or other light sources, for visually indicating to a user characteristics and/or conditions of the device.

2. Background of Related Art

Battery-powered devices, e.g., power tools, electronics, powered surgical instruments, etc., are widely used in many different fields. Many of these battery-powered devices incorporate one or more visual indicators, e.g., LEDs or other light sources, that visually indicate to the user characteristics and/or conditions of the device. For example, by turning the indicator(s) on/off, setting the indicator(s) to output a particular color, setting the indicator(s) to output at a particular brightness, and/or blinking the indicator(s), various different characteristics and/or conditions can be communicated to the user. As can be appreciated, the more easily the user can visualize the indicator(s), the more readily the user is able to ascertain the characteristics and/or conditions that are indicated.

Some battery-powered devices require significant enclosures surrounding the internal electronics of the device, e.g., to protect the internal electronics, inhibit interference, provide insulation, etc. Battery-powered surgical instruments, for example, typically include sealed enclosures surrounding the power generation and control electronics to provide protection, inhibit moisture from reaching the power generation and control electronics, and function as a heat sink to absorb heat produced by the power generation and control electronics. In such and similar configurations, since the indicator(s), which is mounted on the power generation and control electronics, is internally mounted, or “buried” within the enclosure, visualization of the indicator(s) may be limited.

SUMMARY

In accordance with the present disclosure, an assembly for use with a surgical device is provided. The assembly includes an enclosure defining a passageway extending from an interior to an exterior thereof and a visual indicator mounted within the interior of the enclosure adjacent the passageway. The visual indicator is configured to emit light. The passageway is partially defined by a concave surface of the enclosure and/or a chamfered portion of the enclosure to facilitate the passage of light emitted by the visual indicator through the passageway and to the exterior of the enclosure to increase the external viewing angle of the light emitted from the visual indicator.

In aspects, the assembly further includes an outer housing disposed about the enclosure. The outer housing includes an aperture positioned adjacent the passageway to permit passage of light emitted by the visual indicator therethrough for visualization from an exterior of the outer housing.

In aspects, a lens is disposed within the aperture of the outer housing. The light emitted by the visual indicator is configured for passage through the lens for visualization from the exterior of the outer housing.

In aspects, the visual indicator is an LED.

In aspects, electronic circuitry is mounted within the interior of the enclosure. The visual indicator is mounted on the electronic circuitry.

In aspects, the electronic circuitry is disposed on a printed circuit board.

In aspects, the enclosure functions as a heat sink to absorb heat emitted by the electronic circuitry.

In aspects, the passageway is partially defined by one or more concave surfaces of the enclosure and one or more chamfered portions of the enclosure.

In aspects, a thickness of the enclosure is about three or more times greater than a narrow width of the passageway.

In aspects, the visual indicator is displaced from the exterior of the enclosure a distance that is about three or more times greater than a narrow width of the passageway.

Also provided in accordance with the present disclosure is an assembly for use with a surgical device including an outer housing defining a first aperture extending therethrough and an inner enclosure defining a second aperture therethrough. The first and second apertures cooperate to define a passageway extending from an interior of the inner enclosure to an exterior of the outer housing. A visual indicator is mounted within the interior of the inner enclosure adjacent the passageway. The visual indicator is configured to emit light. The passageway is partially defined by a concave surface of the inner enclosure and/or a chamfered portion of the inner enclosure to facilitate the passage of light emitted by the visual indicator through the passageway and to the exterior of the outer housing to increase the external viewing angle of the light emitted from the visual indicator.

In aspects, a lens is disposed within the aperture of the outer housing. The light emitted by the visual indicator is configured for passage through the lens for visualization from the exterior of the outer housing.

In aspects, the visual indicator is an LED.

In aspects, electronic circuitry is mounted within the interior of the inner enclosure. The visual indicator is mounted on the electronic circuitry.

In aspects, the inner enclosure functions as a heat sink to absorb heat emitted by the electronic circuitry.

In aspects, the outer housing functions as a moisture barrier to inhibit moisture from reaching the electronic circuitry.

In aspects, the passageway is partially defined by one or more concave surfaces of the inner enclosure and/or one or more chamfered portions of the inner enclosure.

In aspects, a combined thickness of the inner enclosure and outer housing is about three or more times greater than a narrow width of the passageway.

In aspects, the visual indicator is displaced from the exterior of the outer housing a distance that is about three or more times greater than a narrow width of the passageway.

In aspects, the external viewing angle of the light emitted from the visual indicator in a direction of the narrow width of the passageway is at least about 170 degrees.

DETAILED DESCRIPTION

The present disclosure allows for a greater degree of visualization of visual indicators, e.g., LED's, mounted within battery-powered devices. For example, the features and aspects of the present disclosure allow for a greater degree of visualization of an LED mounted on the power generation and control electronics of a surgical instrument by channeling light emitted from the LED through the enclosure and outer housing of the surgical instrument, and ultimately through an LED lens so as to maximize the viewing angle(s) from which the LED light is viewable from the exterior of the instrument. However, although the present disclosure is primarily described hereinbelow with respect to battery-powered surgical instruments, it is contemplated that the present disclosure be equally applicable for channeling light emitted from any internally mounted visual indicator so as to provide a greater degree of visualization thereof.

Referring now toFIGS. 1 and 2,FIG. 1depicts a battery-powered electrosurgical instrument2andFIG. 2depicts a battery-powered ultrasonic surgical instrument102. For the purposes herein, either an electrosurgical instrument, e.g., instrument2, an ultrasonic surgical instrument, e.g., instrument102, or any other suitable battery-powered device, e.g., surgical instruments, powered tools, electronics, etc., may be utilized in accordance with the present disclosure. Obviously, different considerations apply to each particular type of device, however, the features and aspects of the present disclosure are equally applicable to, and remain generally consistent with respect to any suitable battery-powered device. For the purposes herein, electrosurgical instrument2and ultrasonic surgical instrument102are generally described.

Referring toFIG. 1, electrosurgical instrument2, shown configured as an electrosurgical forceps, generally includes a housing4, a battery assembly18, an electrosurgical generator assembly28, a handle assembly6, a rotating assembly7, a shaft8, a trigger assembly10, a drive assembly (not shown), and an end effector assembly12. End effector assembly12operatively connects to handle assembly6via the drive assembly (not shown) for imparting movement of one or both of jaw members14,16of end effector assembly12between a spaced-apart position and an approximated position for grasping tissue therebetween.

With continued reference toFIG. 1, shaft8is coupled to housing4at proximal end20thereof and extends distally from housing4to define a longitudinal axis “A-A.” End effector assembly12, including jaw members14and16, is disposed at a distal end22of shaft8. End effector assembly12is shown configured as a unilateral assembly wherein jaw member16is fixed relative to shaft8and jaw member14is pivotable relative to jaw member16and shaft8between the spaced-apart position and the approximated position. However, this configuration may be reversed, e.g., wherein jaw member14is fixed relative to shaft8and jaw member16is pivotable relative to jaw member14and shaft8. Alternatively, end effector assembly12may be configured as a bilateral assembly, e.g., wherein both jaw member14and jaw member16are pivotable relative to one another and shaft8between the spaced-apart and approximated positions.

Electrosurgical instrument2may be configured as a bipolar instrument. That is, each of jaw members14,16may include a respective seal plate15,17that is configured to function as an active (or activatable) and/or return electrode. Each seal plate15,17is electrically coupled to generator assembly28via one or more electrical leads (not shown) that extend from generator assembly28, through shaft8, eventually coupling to one or both of seal plates15,17. However, forceps2may alternatively be configured as a monopolar instrument.

Handle assembly6includes a moveable handle40that is movable relative to fixed handle portion42for moving jaw members14,16of end effector assembly12between the spaced-apart and approximated positions. Rotating assembly7rotatable in either direction about longitudinal axis “A-A” to rotate shaft8and, thus, end effector assembly12about longitudinal axis “A-A.” Trigger assembly10is in operable communication with a knife assembly (not shown) including a knife (not shown) that is selectively translatable between jaw members14,16to cut tissue grasped therebetween, e.g., upon actuation of trigger11of trigger assembly10.

With continued reference toFIG. 1, housing4is configured to releasably engage electrosurgical generator assembly28and battery assembly18therein and/or therein. Generator assembly28is releasably engagable with body portion44of housing4, while battery assembly18is releasably engagable with fixed handle portion42of housing4. More specifically, battery assembly18is configured to engage fixed handle portion42of housing4and such that battery assembly18functions as a stationary handle and provides a gripping surface for the user. Generator assembly28releasably engages body portion44of housing4and may be selectively removable therefrom either in connection with removal of battery assembly18or independently thereof. When electrosurgical instrument2is assembled, generator assembly28is disposed in operable communication with battery assembly18to provide electrosurgical energy at one or more suitable frequencies to end effector12for electrosurgically treating tissue, e.g., to seal tissue. In particular, generator assembly28may include electronics that convert the electrical energy from battery assembly18into an RF energy waveform to energize one or both of jaw members14,16. That is, generator assembly28may be configured to transmit RF energy to seal plate15of jaw member14and/or seal plate17of jaw member16to seal tissue. The internal components of generator assembly28will be described below. Activation switch30disposed on housing4is selectively activatable for enabling generator assembly28to generate and subsequently transmit RF energy to seal plate15and/or seal plate17of jaw members14,16, respectively.

Referring now toFIG. 2, ultrasonic instrument102includes components similar to that of electrosurgical instrument2(FIG. 1), namely, a housing104, a battery assembly118, a generator assembly128, a handle assembly106, a shaft108, and an end effector assembly112. Accordingly, only the difference between ultrasonic instrument102and bipolar forceps2(FIG. 1) will be described hereinbelow for purposes of brevity.

Housing104is configured to releasably engage ultrasonic generator assembly128and battery assembly118therein or thereon. Shaft108extends distally from housing104to define longitudinal axis “B-B” and includes end effector assembly112disposed at distal end122thereof. One of jaw members, e.g., jaw member114, of end effector assembly112is movable, upon actuation of moveable handle124, between an open position and a clamping position for grasping between the jaw members114,116. The other jaw member, e.g., jaw member116, serves as an active or oscillating ultrasonic blade that is selectively activatable to seal tissue grasped between jaw members114,116.

Generator assembly128includes a transducer (not shown) configured to convert electrical energy provided by battery assembly118into mechanical energy that produces motion at the end of a waveguide, e.g., at jaw member116. More specifically, generator assembly128is configured to convert the electrical energy provided by battery assembly118into a high voltage AC waveform that drives the transducer (not shown). When the transducer (not shown) and the waveguide are driven at their resonant frequency, mechanical, or ultrasonic motion is produced at jaw member116for sealing tissue grasped between jaw members114,116. Further, an activation button130disposed on housing104is selectively activatable to operate instrument102in two modes of operation: a low-power mode of operation and a high-power mode of operation.

Turning now toFIGS. 3A-6, generator assembly28of electrosurgical instrument2(FIG. 1) is shown and described, although the present disclosure is similarly applicable to battery assembly18of electrosurgical instrument2(FIG. 1), generator assembly128or battery assembly118of ultrasonic instrument102(seeFIG. 2), or any other suitable component of a battery-powered device that includes an internally mounted visual indicator. However, for purposes of simplicity and consistency, exemplary embodiments will be described hereinbelow with reference to generator assembly28of electrosurgical instrument2(FIG. 1) only.

With continued reference toFIGS. 3A-6, generator assembly28includes an outer housing210, an inner enclosure220, internal electronics230including a printed circuit board (PCB) substrate240, and an electrical contact member250. Internal electronics230and, more specifically, PCB substrate240, is mounted within inner enclosure220, which may be a thixoformed magnesium housing that functions as a heat sink to absorb heat produced by internal electronics230, thereby maintaining internal electronics230at an acceptable temperature. Alternatively, inner enclosure220may be formed in any other suitable fashion and/or from any other suitable material(s) to function as a heat sink or for any other suitable purpose. Outer housing210surrounds inner enclosure220and establishes a seal about inner enclosure220and internal electronics230to function as moisture barrier inhibiting the ingress of moisture, i.e., water vapor, into generator assembly28. Inner enclosure220and outer housing210each define an elongated aperture222,212, respectively, extending therethrough, the importance of which will be described below. Apertures222,212may be formed within inner enclosure220and/or outer housing210, respectively, during molding of the respective components or via any other suitable process. Further, a lens214is mounted within elongated aperture212of housing210so as to maintain the seal established by housing210and to facilitate visualization of light emitted from LED260, as will be described in greater detail below. Lens214may be a polycarbonate lens having a refractive index of about 1.60, although any other suitable lens may also be provided.

PCB substrate240of generator assembly28include energy-generating components, e.g., electrosurgical energy-generating components, and control components that facilitate the conversion of electrical energy provided from battery assembly18(FIG. 1) into an RF energy waveform to energize one or both of jaw members14,16of end effector assembly12(FIG. 1). A visual indicator, e.g., an LED260, is mounted on PCB substrate240. LED260may be any suitable LED, e.g., a surface-mounted (SMT) LED mounted on PCB substrate240. LED260functions to indicate, e.g., via turning on/off, changing color, flashing, changing brightness, etc., one or more conditions or states of generator assembly28or surgical instrument2(FIG. 1). Electrical contact member250serves as the electrical communication interface between internal electronics230of generator assembly28and battery assembly18(FIG. 1) and surgical instrument2(FIG. 1) upon engagement of generator assembly28with body portion44of housing4of surgical instrument2(FIG. 1).

Referring still toFIGS. 3A-6, as mentioned above, inner enclosure220and outer housing210each define an elongated aperture222,212, respectively, extending therethrough. Elongated apertures212,222are generally aligned with one another to form an elongated passageway270extending from the interior of generator assembly28to the exterior thereof through inner enclosure220and outer housing210. LED260is mounted on PCB substrate240adjacent an interior end272of passageway270. Lens214is mounted within outer housing210adjacent an exterior end274of passageway270and extends transversely across a top portion of generator assembly28. As such, and as will be described in greater detail below, light emitted from LED260can be channeled through elongated passageway270to lens214, thus allowing light emitted from the internally-displaced LED260to be visualized from the exterior of generator assembly28across relatively wide front-to-back and side-to-side viewing angles θ1and θ2, respectively (seeFIGS. 3A and 3B, respectively). Further, elongated passageway270and lens214may be positioned at or adjacent a longitudinal apex portion29a(seeFIG. 3A) and/or a transverse apex portion29b(seeFIG. 3B) of generator assembly28so as to maximize the front-to-back and side-to-side viewing angles θ1and θ2, respectively (seeFIGS. 3A and 3B, respectively) of light emitted from LED260. However, it is also contemplated that elongated apertures212,222may extend in any suitable direction and/or be disposed in any suitable position, depending on a particular purpose and/or configuration of the device (or component thereof) being used.

With particular reference toFIG. 6, due to the configuration of generator assembly28, wherein LED260is mounted on PCB substrate240, which is disposed within both inner enclosure220and outer housing210, LED260is necessarily internally-displaced from lens214and the exterior of generator assembly28. More specifically, outer housing210may define a thickness, in the vicinity of LED260, of about 0.04 inches (1.0 mm), while inner enclosure220may define a thickness, in the vicinity of LED260, of about 0.28 inches (7.1 mm), although other thicknesses are also contemplated. As such, LED260is internally-displaced from lens214a distance of at least about 0.32 inches (8.1 mm). As mentioned above, elongated apertures212,222defined through outer housing210and inner enclosure220, respectively, cooperate to define elongated passageway270, through which light emitted from LED260is channeled to lens214for visualization from the exterior of generator assembly28. The elongated configurations of passageway270and lens214allow for a relatively wide side-to-side viewing angle θ2(FIG. 3B). However, as can be appreciated, requiring that the light emitted by LED260travel through the relatively narrow elongated passageway270prior to reaching lens214limits the front-to-back viewing angle θ1from which light emitted from LED260can be visualized from the exterior of generator assembly28. The width of lens214(in the narrow direction) may be about 0.1 inches (2.5 mm), although other widths are also contemplated.

In order to allow for a relatively wide longitudinal viewing angle θ1despite the fact that LED260is internally-displaced from lens214and the exterior of generator assembly28and the fact that passageway270defines a relatively narrow configuration, inner enclosure220(and/or outer housing210) is configured such that the elongated aperture222thereof, which defines at least a portion of passageway270, includes reflecting/channeling features that reflect and channel light emitted from LED260through passageway270to lens214to maximize the front-to-back viewing angle θ1from the exterior of generator assembly28.

The above-mentioned reflecting/channeling features may include concave surfaces275,276of inner enclosure220that define passageway270in the transverse direction (as shown), although other configurations are also contemplated. Forming passageway270via the concave surfaces275,276of inner enclosure220allows light that is reflected off surfaces275,276and received by lens214to have greater angles of incidence, thus allowing for an increased front-to-back viewing angle θ1without the need to substantially alter the width of elongated aperture222, which may reduce the overall effectiveness of outer housing210and/or inner enclosure220, e.g., the moisture barrier and/or heat sinking effects thereof. Additionally or alternatively, the inner corners278,279of inner enclosure220that define the interior end272of passageway270may be chamfered so as to allow light emitted from LED260to have greater angles of incidence on surfaces275,276which, in turn, allows for greater angles of incidence on lens214, likewise allowing for an increased front-to-back viewing angle θ1without the need to substantially alter the width of elongated aperture222. It has been found that, using the above-noted dimensions and configuration, a front-to-back viewing angle θ1of greater than 170 degrees, e.g., about 174 degrees, can be achieved, while a side-to-side viewing angle of equal to or greater than about 220 degrees can be achieved.