Patent Publication Number: US-2023139668-A1

Title: Connector system and method for connecting an electrosurgical instrument to an electrosurgical generator

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
     This application claims the benefit of, and priority to, U.S. Provisional Patent Application No. 63/274,599, filed on Nov. 2, 2021, the entire contents of which are hereby incorporated herein by reference. 
    
    
     FIELD 
     This disclosure generally relates to electrosurgical instruments, and more particularly, to connector systems for selectively connecting electrosurgical instruments to an electrosurgical generator. 
     BACKGROUND 
     Electrosurgical instruments are employed by surgeons to perform a variety of endoscopic, robotic, and/or open surgical procedures for treating tissue including cutting, coagulating, cauterizing, desiccating, and/or sealing tissue. High frequency electrical power, typically radio frequency (RF) power or energy, is produced by an electrosurgical generator and applied to the tissue by the electrosurgical instrument. The electrosurgical instrument is operated and manipulated by a surgeon or a surgical robot to perform the desired electrosurgical procedure. 
     The connection between the electrosurgical instrument and the electrosurgical generator is typically removable, such that the electrosurgical instrument may be connected and disconnected from the electrosurgical generator over the course of a single procedure, over a number of electrosurgical procedures, and/or a first electrosurgical instrument configured for performing a first type of surgical procedure may be connected and disconnected from the electrosurgical generator and a second electrosurgical instrument configured for performing a second type of surgical procedure may be connected to the electrosurgical generator. 
     SUMMARY 
     This disclosure relates to connector systems for connecting electrosurgical instruments to an electrosurgical generator. The electrosurgical instruments include a connector which provides a reliable and easily insertable and removable, physical and electrical connection to a connector of the electrosurgical generator. In aspects, the connector systems are designed to reduce wear on the conductive surfaces of the connectors of the electrosurgical instrument and the electrosurgical generator thereby increasing reliability of the connection between the electrosurgical instrument and the electrosurgical generator. In some aspects, the connector systems are designed to encode information on the connector of the electrosurgical instrument and communicate that information to the electrosurgical generator for identifying the electrosurgical instrument connected to the electrosurgical generator, detecting if incorrect or incomplete insertion of the connector of the electrosurgical instrument into the connector of the electrosurgical generator is made, and/or allowing for make-before-break or make-before-make functions to be employed, thereby increasing electrosurgical instrument and electrosurgical generator reliability. 
     In aspects, this disclosure provides a connector system for connecting an electrosurgical instrument to an electrosurgical generator. The connector system includes a connector plug coupled to the electrosurgical instrument and a plug receptacle defined in the electrosurgical generator. The connector plug includes a connector housing and a connector pin extending from the connector housing, and the connector pin includes an elongated body and a protrusion extending laterally outwardly from the elongated body. The plug receptacle includes an electrical connector disposed therein, and the electrical connector includes a substrate having a notch defined therein and an electrical contact region disposed thereon. The connector plug is removably insertable into the plug receptacle such that the protrusion of the connector pin is positioned within the notch of the electrical connector and the elongated body of the connector pin contacts the electrical contact region of the electrical connector. 
     In some aspects, the protrusion of the connector pin is positioned between proximal and distal segments of the elongated body. In certain aspects, the notch defined in the electrical connector is proximal to the electrical contact region and the distal segment of the connector pin contacts the electrical contact region when the connector plug is inserted in the plug receptacle. 
     In some aspects, the notch and the electrical contact region of the electrical connector is defined on a first surface of the substrate. In certain aspects, the notch and the electrical contact region are disposed on a planar segment of the first surface, and the first surface includes a tapered segment disposed proximal to the planar segment. 
     The protrusion of the connector pin and the notch of the electrical connector may have complementary geometries. The elongated body of the connector pin may be formed from a conductive material and the protrusion may be formed from a non-conductive material. The electrical connector may be a printed circuit board. The connector pin of the connector plug may be one of a plurality of connector pins and the electrical connector of the plug receptacle may be one of a plurality of electrical connectors, and the plurality of connector pins may be aligned with the plurality of electrical connectors. 
     In some aspects, during insertion of the connector plug into the plug receptacle, the protrusion of the connector pin is configured to slide along the substrate of the electrical connector such that the elongated body of the connector pin does not contact the electrical connector until the protrusion aligns with the notch of the electrical connector. 
     In aspects, this disclosure provides an electrosurgical system including an electrosurgical instrument including a connector plug and an electrosurgical generator including a plug receptacle. The connector plug includes a connector housing and a connector pin extending from the connector housing, and the connector pin includes an elongated body and a protrusion extending laterally outwardly from the elongated body. The plug receptacle includes an electrical connector disposed therein, and the electrical connector includes a substrate having a notch defined therein and an electrical contact region disposed thereon. The connector plug is removably insertable into the plug receptacle such that the protrusion of the connector pin is positioned within the notch of the electrical connector and the elongated body of the connector pin contacts the electrical contact region of the electrical connector. 
     In some aspects, the protrusion of the connector pin is positioned between proximal and distal segments of the elongated body. In certain aspects, the notch defined in the electrical connector is proximal to the electrical contact region and the distal segment of the connector pin contacts the electrical contact region when the connector plug is inserted in the plug receptacle. 
     In some aspects, the notch and the electrical contact region of the electrical connector is defined on a first surface of the substrate. In certain aspects, the notch and the electrical contact region are disposed on a planar segment of the first surface, and the first surface includes a tapered segment disposed proximal to the planar segment. 
     The protrusion of the connector pin and the notch of the electrical connector may have complementary geometries. The elongated body of the connector pin may be formed from a conductive material and the protrusion may be formed from a non-conductive material. The electrical connector may be a printed circuit board. The connector pin of the connector plug may be one of a plurality of connector pins and the electrical connector of the plug receptacle may be one of a plurality of electrical connectors, and the plurality of connector pins may be aligned with the plurality of electrical connectors. 
     In some aspects, during insertion of the connector plug into the plug receptacle, the protrusion of the connector pin is configured to slide along the substrate of the electrical connector such that the elongated body of the connector pin does not contact the electrical connector until the protrusion aligns with the notch of the electrical connector. 
     In aspects, this disclosure provides a method of using an electrosurgical system including: connecting an electrosurgical instrument to an electrosurgical generator by inserting a connector plug of the electrosurgical instrument into a plug receptacle of the electrosurgical generator such that a protrusion of a connector pin of the connector plug is positioned within a notch defined in an electrical connector disposed within the plug receptacle, and an elongated body of the connector pin contacts an electrical contact region of the electrical connector. 
     The method may further include: inserting an end effector of the electrosurgical instrument into tissue; and actuating an energy activation actuator to control a supply of energy from the electrosurgical generator to the end effector of the electrosurgical instrument. 
     The details of one or more aspects of this disclosure are set forth in the accompanying drawings and the description below. Other aspects, as well as features, objects, and advantages of the aspects described in this disclosure will be apparent from the description and drawings, and from the claims. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       Various aspects of this disclosure are described hereinbelow with reference to the drawings, which are incorporated in and constitute a part of this specification, wherein: 
         FIG.  1    is a perspective view of an electrosurgical system including an electrosurgical instrument and an electrosurgical generator in accordance with aspects of the disclosure; 
         FIG.  2    is a perspective view of a connector system of the electrosurgical assembly of  FIG.  1   , showing a connector plug of the electrosurgical instrument connected to a plug receptacle of the electrosurgical generator; 
         FIG.  3 A  is a partial, side view of a connector pin of the connector plug of  FIG.  2    and an electrical connector disposed within the plug receptacle of  FIG.  2   , shown prior to insertion of the connector plug into the plug receptacle; 
         FIG.  3 B  is a partial, side view of the connector pin of  FIG.  3 A  contacting the electrical connector of  FIG.  3 A  during insertion of the connector plug into the plug receptacle; 
         FIG.  3 C  is a partial, side view of the connector pin of  FIG.  3 B  physically and electrically connected to the electrical connector of  FIG.  3 B ; 
         FIG.  4    is a perspective view of another electrosurgical instrument suitable for use with the electrosurgical generator of  FIG.  1   ; and 
         FIG.  5    is a perspective view of yet another electrosurgical instrument suitable for use with the electrosurgical generator of  FIG.  1   . 
     
    
    
     DETAILED DESCRIPTION 
     Aspects of this disclosure will now be described in detail with reference to the drawing figures wherein like reference numerals identify similar or identical elements. It should be understood that various components of the disclosure, such as those plainly numbered, correspond to components of the disclosure prime or double prime numbered, such that redundant explanation of similar components need not be repeated herein. Throughout this description, the term “proximal” refers to a portion of a structure, or component thereof, that is closer to an operator (whether a human surgeon, other medical professional, or a surgical robot), and the term “distal” refers to a portion of the structure, or component thereof, that is farther from the operator. It should be understood that the disclosed aspects are merely exemplary of the disclosure and may be embodied in various forms. Well-known functions or constructions are not described in detail to avoid obscuring the disclosure in unnecessary detail. Therefore, specific structural and functional details disclosed herein are not to be interpreted as limiting, but merely as a basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the disclosure in virtually any appropriately detailed structure. 
       FIG.  1    illustrates an electrosurgical system  10  including an electrosurgical instrument  100  and an electrosurgical generator  200 . The electrosurgical instrument  100  is electrically connectable to the electrosurgical generator  200 . The electrosurgical instrument  100  is shown in the form of an endoscopic forceps and includes a housing  110  including a handle assembly  112 , an elongated shaft  120  extending distally from the housing  110 , and an end effector  130  disposed at a distal end of the elongated shaft  120 . Various internal operating components of the electrosurgical instrument  100  are stored within the housing  110 , the elongated shaft  120 , and the end effector  130 , and the end effector  130  is configured to treat tissue of a patient. The end effector  130  includes first and second jaws  132   a,    132   b  that cooperate to rotate, articulate, grasp, seal, and/or divide tissue. The first and second jaws  132   a,    132   b  include respective sealing plates  134   a,    134   b  which communicate electrosurgical energy through tissue held therebetween. The electrosurgical instrument  100  also includes a cable  140  having a connector plug  150  at a distal end thereof which connects the electrosurgical instrument  100  to the electrosurgical generator  200 . The cable  140  is internally divided into cable leads which each transmit electrosurgical energy through their respective feed paths through the electrosurgical instrument  100  and to the end effector  130  when the connector plug  150  is coupled to the electrosurgical generator  200 . Control leads may also be provide to communicatively couple electrosurgical instrument  100  and electrosurgical generator  200 . 
     The electrosurgical generator  200  is source of electrosurgical energy, such as radiofrequency energy, which is connectable to the electrosurgical instrument  100  for transmitting the electrosurgical energy therethrough. The electrosurgical generator  200  includes a plug receptacle  210  configured to receive the connector plug  150  of the electrosurgical instrument  100 , a control panel  220  that provides an interface for the user, and may include an energy activation actuator  230 , such as a foot pedal, for enabling selective activation of electrosurgical energy from the electrosurgical generator  200  to the electrosurgical instrument  100 . The electrosurgical generator  200  may be configured to be selectively set (e.g., via the control panel  220 ) to an energy frequency or signal appropriate for the attached electrosurgical instrument  100  and/or the electrosurgical procedure being performed, or the electrosurgical generator  200  may be configured to automatically configure itself to transmit a particular energy frequency or signal depending, for example, on the electrosurgical instrument  100  connected thereto. It should be understood that the electrosurgical generator  200  may use different sources of energy such as, for example, high frequency, ultrasound, thermal, microwave, light, or molecular resonance, utilizing different techniques (e.g., monopolar or bipolar) and, in some aspects, other medical or surgical delivery sources may be used, such as, for example, lasers, hydro dissectors, or aspirators. 
       FIGS.  1  and  2    illustrate a connector system  20  of the electrosurgical system  10 . The connector system  20  includes the connector plug  150  of the electrosurgical instrument and the plug receptacle  210  of the electrosurgical generator  200 . The connector plug  150  is positionable within the plug receptacle  210  and configured to mechanically engage the plug receptacle  210  to create an electrical connection between the electrosurgical instrument  150  and the electrosurgical generator  200  for delivery of the electrosurgical energy. 
     As seen in  FIG.  2   , the connector plug  150  includes a connector housing  152  and connector pins  154  extending distally from the connector housing  152 . Each of the connector pins  154  includes an elongated body  156  extending along a longitudinal axis “X.” The elongated body  156  has a generally cylindrical shape, and includes a proximal segment  156   a  and a distal segment  156   b  terminating at a distal tip  156   c.  A protrusion  157  extends laterally (in aspects, radially) outwardly from the elongated body  156  and is positioned between the proximal and distal segments  156   a,    156   b  of the elongated body  156  such that the portion of the elongated body  156  including the protrusion  157  has a larger diameter or dimension than the rest of the elongated body  156 . The protrusion  157  may be a bump, ridge, or other projection having a generally rounded or curve profile that extends partially or entirely around the elongated body  156  such that the protrusion  157  is configured to contact and engage an electrical connector  240  of the plug receptacle  210 , as described in further detail below. 
     In some aspects, the protrusion  157  is integrally formed with the elongated body  156  (e.g., stamping or injection molding) and, in some aspects, the protrusion  157  is secured to the elongated body  156  (e.g., electroplating or over-molding). The elongate body  156  of the connector pin  156  is formed from a conductive material, such as gold, copper, or stainless steel, and is coupled to a cable lead of the cable  140  such that when electrical connection is made with the electrosurgical generator  200 , energy is transmitted through the electrosurgical instrument  100 . In some aspects, the protrusion  157  is formed from the same or different conductive material as the elongated body  156 , however, the protrusion  157  may be formed from any material (e.g., a non-conductive material, such as a polymer or plastic) of sufficient strength and rigidity to withstand frictional wear and tear during insertion and removal of the connector plug  150  into and out of the plug receptacle  210 . 
     While the elongated body  156  of the connector pins  154  are shown having a substantially cylindrical shape, it should be understood that the elongated body  156  may have other shapes, such as substantially rectangular blades. Further, while the connector plug  150  is shown including two connector pins  154 , it should be understood that the number of connector pins  154 , as well as the size, shape, and/or placement of the connector pins  154  may vary. 
     The plug receptacle  210  of the electrosurgical generator  200  defines a cavity  211  therein that is sized and shaped to receive the connector plug  150 . The cavity  211  includes a proximal portion  211   a  sized and shaped to receive the connector housing  152  of the connector plug  150  in a friction fit manner, and a distal portion  211   b  having electrical connectors  240  extending therein that are each aligned and configured to interface with a respective connector pin  154  of the connector plug  150 . The plug receptacle  210  of the electrosurgical generator  200  may be configured to receive or connect to connector plugs of various electrosurgical instruments, and/or may be configured to receive or connect to electrosurgical instruments which includes more or less connector pins. 
     As shown in  FIG.  3 A , the electrical connector  240  is shown in the form of a printed circuit board including a body or substrate  242  supporting an electrical contact region  244  thereon (e.g., a terminal end of a conductive trace defined through the substrate  242 ). The electrical contact region  244  is formed from a conductive material, such as copper, and the substrate  242  is formed from a non-conductive material, such as a polymer or a ceramic. The electrical connector  240  enables communication between the electrosurgical generator  200  and the electrosurgical instrument  100  and transmittal of electrosurgical energy from the electrosurgical generator  200  to the electrosurgical instrument  100 . In some aspects, the electrical connector  240  includes electronic components supporting an encoding scheme that identifies and/or recognizes the presence and/or type of a connector pin  154  and communicates information about the electrosurgical instrument  100  and/or the connection therewith to the electrosurgical generator  200 . In certain aspects, the connector system  20  enables communication between sensor(s) of the electrosurgical instrument  100  and/or electrosurgical generator  200 . 
     The substrate  242  of the electrical connector  240  has a generally planar profile and includes opposed first and second surfaces  246 ,  248 . The first surface  246  includes a sloped or tapered segment  247  extending to a proximal end  242   a  of the substrate  242 , a notch  249  defined in the first surface  246  distal to and in axially spaced relation relative to the tapered segment  247 , and the electrical contact region  244  disposed distal to and in spaced relation relative to the notch  249 . The notch  249  has a complementary geometry with the protrusion  157  of the connector pin  154 . The second surface  248  of the substrate  242  may be a mirror image of the first surface  246 . 
     During insertion of the connector plug  150  into the plug receptacle  210 , as seen in  FIG.  3 A , the distal tip  156   c  of the connector pin  154  slides adjacent to the proximal end  242   a  of the substrate  242  of the electrical connector  240  until the protrusion  157  of the connector pin  154  contacts the electrical connector  240 . The protrusion  157  initially slides against the tapered segment  247  of the first surface  246  and deflects the connector pin  154  laterally outwardly away from its biased position, as shown in  FIG.  3 B , as the protrusion  157  moves distally along the first surface  246  of the electrical connector  240 . The connector pin  154  continues its distal movement along the first surface  246  of the electrical connector  240  until the protrusion  157  of the connector pin  154  aligns with and drops down into the notch  249  of the electrical connector  240  whereby the connector pin  154  returns to its biased position, as shown in  FIG.  3 C , such that the distal segment  156   b  of the connector pin  154  contacts the electrical contact region  244  of the electrical connector  240  thereby making a physical connection between the connector pin  154  and the electrical connector  240  and enabling communication between the electrosurgical instrument  100  and the electrosurgical generator  200 . 
     The tapered segment  247  and the notch  249  of the electrical connector  240  and the protrusion  157  of the connector pin  154  work together to ensure contact of the distal segment  156   b  of the connector pin  154  with the electrical contact region  244  of the electrical connector  240  once the connector plug  150  is fully inserted into the plug receptacle  210 , while minimizing or preventing wear on these critical conductive areas (e.g., the distal segment  156   b  of the connector pin  154  and the electrical contact region  244  of the electrical connector  240 ) during the insertion and removal processes. In some aspects, the distal segment  156   b  of the connector pin  154  has limited contact and, in certain aspects, no contact, with any portion of the electrical connector  240  until the protrusion  157  enters the notch  249  and the distal segment  156   b  is deflected into contact with the electrical contact region  244  of the electrical connector  240  (e.g., only the protrusion  157  contacts the electrical connector  240  during sliding of the connector plug  150  into the plug receptacle  210 ). 
     Referring also to  FIG.  1   , during operation of the electrosurgical instrument  10 , with the connector plug  150  engaged within the plug receptacle  210  of the electrosurgical generator  200  and the end effector  130  positioned within tissue of a patient, a user controls the supply of energy to the end effector  130  of the electrosurgical instrument  100  by depressing an energy activation actuator  114  supported on the electrosurgical instrument  100  or an energy activation actuator  230  coupled to the electrosurgical generator  200 . Specifically, the connector pins  154  are electrically coupled to the electrical contact regions  244  in the plug receptacle  240  thereby providing a path for the electrosurgical energy through the electrosurgical instrument  100  and to tissue of a patient via the end effector  130 . 
     After the user is finished using the electrosurgical instrument  100 , the connector plug  150  is removed from the plug receptacle  210 . When the connector plug  150  is removed, the protrusion  157  of the connector pin  154  slides out of the notch  249  defined in the electrical connector  240 , across the first surface  246  of the substrate  242 , and along the tapered surface  247  thereby separating the connector plug  150  from the plug receptacle  210  without causing wear on the distal segment  156   b  of the connector pin  154  or the electrical contact region  244  of the electrical connector  240 . 
     While the electrosurgical instrument  100  is shown as an endoscopic forceps in  FIG.  1   , the electrosurgical system  10  may additionally or alternatively include other electrosurgical instruments which are electrically connectable to the electrosurgical generator  200 , such as those shown in  FIGS.  4  and  5   , although other instruments including robotic surgical instruments are also contemplated.  FIG.  4    illustrates an electrosurgical instrument  100 ′ in the form of an open forceps which includes first and second elongated shafts  120   a ′,  120   b ′ pivotably coupled together. Proximal end portions of the first and second elongated shafts  120   a ′,  120   b ′ include first and second handles  122   a ′,  122   b ′, and distal end portions of the first and second elongated shafts  120   a ′,  120   b ′ cooperate to define an end effector  130 ′ having opposed first and second jaws  132   a ′,  132   b ′ including sealing plates  134   a ′,  134   b ′ therein. A cable  140 ′ extends from the first elongated shaft  120   a ′ and has a connector plug  150 ′ at a distal end thereof.  FIG.  5    illustrates an electrosurgical device  100 ″ in the form of an electrosurgical pencil that includes an elongate housing  110 ″ supporting an end effector  130 ′ having an electrocautery blade  136 ″. A cable  140 ″ extends from the elongate housing  110 ″ and has a connector plug  150 ″ at a distal end thereof 
     The connector plugs  150 ′,  150 ″ are configured for insertion into and removal from the plug receptacle  210  ( FIG.  1   ) of the electrosurgical generator  200  in the same or similar manner as the connector plug  150  of the electrosurgical instrument  100  of  FIG.  1   . Accordingly, it should be understood that the electrosurgical instrument may be endoscopic or open, and the end effector of the electrosurgical instrument may have any suitable type of electrosurgical electrode or electrode assembly for delivering any suitable type of electrosurgical energy, and the plug receptacle of the electrosurgical generator may be configured to accommodate connector plugs of these electrosurgical instruments. 
     While aspects of the disclosure are discussed in terms of connector systems for interconnecting an electrosurgical instrument to an electrosurgical generator, it is envisioned that the principles of this disclosure are equally applicable to a range of connector systems for electrically interconnecting various instruments and equipment, as well as components thereof, such as removable or replaceable components of a surgical instrument (e.g., an end effector releasably attached an elongated shaft of a surgical instrument). 
     While aspects of the disclosure have been shown in the drawings, it is not intended that the disclosure be limited thereto, as it is intended that the disclosure be as broad in scope as the art will allow and that the specification be read likewise. It is to be understood, therefore, that the disclosure is not limited to the precise aspects described, and that various other changes and modifications may be effected by one skilled in the art without departing from the scope or spirit of the disclosure. Additionally, the elements and features shown and described in connection with certain aspects of the disclosure may be combined with the elements and features of certain other aspects without departing from the scope of the disclosure, and that such modifications and variation are also included within the scope of the disclosure. Therefore, the above description should not be construed as limiting, but merely as exemplifications of aspects of the disclosure. Thus, the scope of the disclosure should be determined by the appended claims and their legal equivalents, rather than by the examples given.