Patent Document

CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application is a divisional application of U.S. patent application Ser. No. 12/827,783, filed on Jun. 30, 2010, the entire content of which is incorporated herein by reference. 
     
    
     BACKGROUND 
       [0002]    1. Technical Field 
         [0003]    The present disclosure relates to apparatuses and method for wirelessly supplying energy to a surgical device, and more particularly, to an inductive RF generator for supplying energy to a wireless surgical device. 
         [0004]    2. Background of Related Art 
         [0005]    Energy-based tissue treatment is well known in the art. Various types of energy (e.g., electrical, ultrasonic, microwave, cryogenic, thermal, laser, etc.) are applied to tissue to achieve a desired result. Electrosurgery involves application of high radio frequency electrical current to a surgical site to cut, ablate, coagulate or seal tissue. In monopolar electrosurgery, as shown in  FIG. 1A , a source or active electrode  2  delivers radio frequency energy from the electrosurgical generator  20  to the tissue and a return electrode  2  carries the current back to the generator. In monopolar electrosurgery, the source electrode is typically part of the surgical instrument held by the surgeon and applied to the tissue to be treated. A patient return electrode is placed remotely from the active electrode to carry the current back to the generator. 
         [0006]    In bipolar electrosurgery, as shown in  FIG. 1B , one of the electrodes of the hand-held instrument functions as the active electrode  14  and the other as the return electrode  16 . The return electrode is placed in close proximity to the active electrode such that an electrical circuit is formed between the two electrodes (e.g., electrosurgical forceps  10 ). In this manner, the applied electrical current is limited to the body tissue positioned immediately adjacent to the electrodes. When the electrodes are sufficiently separated from one another, the electrical circuit is open and thus inadvertent contact with body tissue with either of the separated electrodes does not cause current to flow. 
         [0007]    Electrosurgical instruments have become widely used by surgeons in recent years. By and large, most electrosurgical instruments are hand-held instruments, e.g., an electrosurgical pencil, which transfer radio-frequency (RF) electrical or electrosurgical energy to a tissue site. As used herein the term “electrosurgical pencil” is intended to include instruments which have a handpiece that is attached to an active electrode and which is used to cauterize, coagulate and/or cut tissue. Typically, the electrosurgical pencil may be operated by a handswitch or a foot switch. The active electrode is an electrically conducting element that is usually elongated and may be in the form of a thin flat blade with a pointed or rounded distal end. Alternatively, the active electrode may include an elongated narrow cylindrical needle that is solid or hollow with a flat, rounded, pointed or slanted distal end. Typically electrodes of this sort are known in the art as “blade”, “loop” or “snare”, “needle” or “ball” electrodes. 
         [0008]    As mentioned above, the handpiece of the electrosurgical pencil is connected to a suitable electrosurgical energy source (i.e., generator) which produces the radio-frequency electrical energy necessary for the operation of the electrosurgical pencil. In general, when an operation is performed on a patient with an electrosurgical pencil, electrical energy from the electrosurgical generator is conducted through the active electrode to the tissue at the site of the operation and then through the patient to a return electrode. The return electrode is typically placed at a convenient place on the patient&#39;s body and is attached to the generator by a conductive material. 
         [0009]    Some electrosurgical procedures utilize electrosurgical forceps that use both mechanical clamping action and electrical energy to affect hemostasis by heating tissue and blood vessels to coagulate, cauterize and/or seal tissue. As an alternative to open forceps for use with open surgical procedures, many modern surgeons use endoscopes and endoscopic instruments for remotely accessing organs through smaller, puncture-like incisions. As a direct result thereof, patients tend to benefit from less scarring and reduced healing time. 
         [0010]    Endoscopic instruments are typically inserted into the patient through a cannula, or port, which has been made with a trocar. Typical sizes for cannulas range from three millimeters to twelve millimeters. Smaller cannulas are usually preferred, which, as can be appreciated, ultimately presents a design challenge to instrument manufacturers who must find ways to make endoscopic instruments that fit through the smaller cannulas. Such endoscopic instruments may use monopolar forceps, bipolar forceps or a combination monopolar/bipolar forceps. 
         [0011]    Generators have a fixed number of inputs for connecting surgical devices using cables. The use of many cables can cause entanglement of the cables as the surgeon performs the surgery. Additionally, the cables used to connect the surgical devices have substantial weight, where the substantial weight of the cable can cause strain on the surgeon during long surgeries. 
       SUMMARY 
       [0012]    In accordance with the present disclosure, a system and method for wirelessly powering an electrosurgical device using a generator to generate a radio frequency (RF) energy field. A switch on the electrosurgical device sends a wireless signal to the generator, where the generator allows a current to pass through an inductive coil to generate the RF energy field. The RF energy field induces a current to flow across an inductive coil within the electrosurgical device. The current flow is then processed though a RF conditioning circuit and outputted to the end effector assembly of the device. 
         [0013]    According to an embodiment of the present disclosure, a method for wirelessly operating a hand held electrosurgical device includes the steps of selecting a switch on the hand held electrosurgical device and sending an instruction wirelessly to a generator to generate an RF energy field. The method further includes the steps of generating the RF energy field and the RF energy field inducing a current across an inductor within the hand held device that causes a RF signal. The method also includes the step of supplying the RF signal to an end effector assembly to perform a surgical procedure. 
         [0014]    According to another embodiment of the present disclosure, a system for wirelessly operating a hand held electrosurgical device. The system includes a generator and a hand held electrosurgical device. The generator includes a power source and a first inductor to generate a RF energy field. The hand held electrosurgical device includes a second inductor, a power board, a wireless communication board, a control interface, and an end effector assembly. The control interface includes at least one switch and is configured to send a first message to the wireless communication board when the at least one switch is selected. The wireless communication board, in response to receiving the first message from the control interface, sends a second message to the generator instructing the generator to generate the RF energy field. The power board receives a RF signal from the second inductor when the RF energy field induces a current across the second inductor, and sends the RF signal to the end effector. 
         [0015]    According to another embodiment of the present disclosure, a method for wirelessly operating a hand held electrosurgical device includes the steps of generating a RF energy field and selecting a switch on the device to select a mode of operation. The RF energy field induces a current across an inductor within the device that causes a RF signal. The method further includes the steps of conditioning the RF signal into the selected mode, and supplying the conditioned RF signal to an end effector assembly to perform a surgical procedure. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]    The above and other aspects, features, and advantages of the present disclosure will become more apparent in light of the following detailed description when taken in conjunction with the accompanying drawings in which: 
           [0017]      FIGS. 1A-1B  are schematic diagrams of electrosurgical systems; 
           [0018]      FIG. 2  is a perspective view of an electrosurgical pencil and generator in accordance with an embodiment of the present disclosure; 
           [0019]      FIG. 3  is a partially broken away, side elevational view of the electrosurgical pencil of  FIG. 2 ; 
           [0020]      FIG. 4  is a schematic diagram of a wireless RF system according to an embodiment of the present disclosure; 
           [0021]      FIG. 5A  is a perspective view of an endoscopic forceps and generator according to the present disclosure; 
           [0022]      FIG. 5B  is interior perspective view of the endoscopic forceps of  FIG. 16A  according to the present disclosure; and 
           [0023]      FIG. 6  is a flow chart of a wireless RF system according to the present disclosure. 
       
    
    
     DETAILED DESCRIPTION 
       [0024]    Particular embodiments of the present disclosure are described hereinbelow with reference to the accompanying drawings; however, it is to be understood that the disclosed embodiments 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 present 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 present disclosure in virtually any appropriately detailed structure. 
         [0025]    Like reference numerals may refer to similar or identical elements throughout the description of the figures. As shown in the drawings and described throughout the following description, as is traditional when referring to relative positioning on a surgical instrument, the term “proximal” refers to the end of the apparatus which is closer to the user and the term “distal” refers to the end of the apparatus which is further away from the user. 
         [0026]    Electromagnetic energy is generally classified by increasing energy or decreasing wavelength into radio waves, microwaves, infrared, visible light, ultraviolet, X-rays and gamma-rays. As used herein, the term “microwave” generally refers to electromagnetic waves in the frequency range of 300 megahertz (MHz) (3×10 8  cycles/second) to 300 gigahertz (GHz) (3×10 11  cycles/second). As used herein, the term “RF” generally refers to electromagnetic waves having a lower frequency than microwaves. 
         [0027]      FIGS. 2-3  show an electrosurgical pencil constructed in accordance with an embodiment of the present disclosure is shown generally as  100 . Electrosurgical pencil  100  includes an elongated housing  102  configured and adapted to support a blade receptacle  104  at a distal end  103  thereof which, in turn, receives a replaceable electrocautery end effector  106  in the form of a loop and/or blade therein. Electrocautery blade  106  is understood to include a planar blade, a loop, a needle and the like. A distal end portion  108  of blade  106  extends distally from receptacle  104  while a proximal end portion of blade  106  is retained within distal end  103  of housing  102 . Electrocautery blade  106  may be fabricated from a conductive type material, such as, for example, stainless steel, or is coated with an electrically conductive material. The electrosurgical pencil also includes a power board “P”, a wireless communication board “W”, and a controller board “C”. 
         [0028]    As shown, electrosurgical pencil  100  is coupled to a return pad “R” via a cable  112 . Cable  112  includes a transmission wire which electrically interconnects return pad “R” with return port  111  of electrosurgical pencil  100 . Alternatively, the return pad “R” can be connected to the generator “G”. 
         [0029]    For the purposes herein, the terms “switch” or “switches” includes electrical actuators, mechanical actuators, electro-mechanical actuators (rotatable actuators, pivotable actuators, toggle-like actuators, buttons, etc.) or optical actuators. 
         [0030]    Electrosurgical pencil  100  includes at least one activation switch, e.g., three activation switches  124   a - 124   c,  each of which are supported on an outer surface  107  of housing  102 . Each activation switch  124   a - 124   c  is operatively connected to a respective switch  126   a - 126   c  which, in turn, controls the transmission of RF electrical energy supplied from a power board “P” and an electrosurgical generator “G” to electrosurgical blade  106 . More particularly, switches  126   a - 126   c  are electrically coupled to control loop  116  and are configured to close and/or complete control loop  116 , which causes the controller board “C” to send an instruction to the wireless communication board “W”. The wireless communication board “W” sends a wireless signal using antenna  140  to the electrosurgical generator “G” to generate an RF energy field  200 . The RF energy field  200  causes a current to flow though an inductor  150  connected to power board “P”. As the current flows through inductor  150 , energy is transmitted to electrocautery blade  106  to perform surgical operation. 
         [0031]    In an alternative embodiment, the RF energy field  200  can be continuously in an “on” mode by selecting a switch on the electrosurgical device  100  or on the electrosurgical generator “G”. Additionally, switches  124   a - 124   c  can be used to supply energy in an operational mode selected by the user without sending information to the electrosurgical generator “G”, where the power board “P” conditions the RF signal from inductor  150  into the selected operational mode. The operational mode can be cut, ablate, coagulate, or seal depending on the surgical instrument being employed. 
         [0032]    Electrosurgical pencil  100  further includes one or more intensity controllers  128   a  and/or  128   b,  each of which are slidingly supported in guide channels  130   a,    130   b,  respectively, which are formed in outer surface  107  of housing  102 . Each intensity controller  128   a  and  128   b  is a slide-like potentiometer. Each intensity controller  128   a  and  128   b  and respective guide channel  130   a  and  130   b  may be provided with a series of cooperating discreet or detented positions defining a series of positions to allow easy selection of output intensity from a minimum amount to a maximum amount. The series of cooperating discreet or detented positions also provide the surgeon with a degree of tactile feedback. One of the series of positions for intensity controllers  128   a,    128   b  may be an “off” position (i.e., no level of electrical or RF energy is being transmitted). 
         [0033]    Intensity controllers  128   a  and  128   b  are configured and adapted to adjust one of the power parameters (e.g., RF energy field, voltage, power and/or current intensity) and/or the power verses impedance curve shape to affect the perceived output intensity. 
         [0034]    As shown in  FIG. 3 , electrosurgical pencil  100  may include a controller board “C”, a wireless communication board “W”, and a power board “P” within housing  102 . Controller board “C” receives inputs from the various switches, intensity controller, nubs, potentiometers or the like that may be disposed in housing  102  and outputs a signal to wireless communication board “W” that, in turn, sends a wireless signal though antenna  140  to the generator “G” to generate RF energy field  200  from a generator side inductor  160  connected to a power source  430 . An inductor  150  is connected to a power board “P”, and the RF energy field  200  induces a current to flow through inductor  150 . The power board “P” then sends an energy signal to electrosurgical blade  106 . The type of energy signal sent to the electrosurgical blade  106  may be controlled through the controller board “C” using switches  124   a - 124   c  and/or  128   a - 128   b.    
         [0035]    Alternatively, the electrosurgical pencil  100  may include a rechargeable battery (not shown). The battery may be recharged when RF field  200  induces a current to flow through inductor  150 . The battery then supplies the energy signal through the power board “P” to the electrosurgical blade  106 . 
         [0036]    In another embodiment, the electrosurgical pencil  100  may include a capacitor (not shown). The capacitor may be charged when RF field  200  induces a current to flow through inductor  150 . The capacitor then supplies the energy signal through the power board “P” to the electrosurgical blade  106 . For example, the capacitor may take 20 seconds to charge and provide a 20 second burst of electrical energy to the power board “P” to supply to the electrosurgical blade  106 . [Please give a size range of capacitor that may be possible to use] 
         [0037]      FIG. 4  discloses a schematic of a wireless RF system  400  to power an electrosurgical device  100  or  510  (see  FIGS. 2 and 5   a , respectively). An electrosurgical device  405 , such as electrosurgical device  100  or  510 , includes a control interface  450 , inductive power circuitry  440 , an inductor  150 , wireless communication circuitry  460 , and/or a device electrode or seal plate  470 . 
         [0038]    A generator “G” includes at least an inductor  160  connected to a power source  430 . The inductor  160  may be a single inductor with an inductance between about XX and XX [please give a range for the inductance]. Alternatively, inductor  160  may be two or more inductors connected in series or parallel. The inductor  160  generates an RF energy field  200 . [what is the formula for calculating size of RF energy field and what is the size range of the RF energy field] The RF energy field  200  causes a current to flow through inductor  150 . The inductor  150  is connected to inductive power circuitry  440 , where the inductive power circuitry filters and/or conditions the RF signal. The RF signal may be conditioned based on the selected mode. The RF signal is then sent to the electrode  106  (See  FIG. 2 ) or seal plate  528  (See  FIG. 5   a ) of the device. 
         [0039]    The control interface  450  is an interface between an operator and the device  405 . The control interface  450  includes one or more switches, such as switches  124   a - 124   c,  that allow the operator to select the mode for operating the device  405 . The control interface  450  is connected to the wireless communication circuitry  460 . The wireless communication circuitry  460  relays the mode selected from the control interface  450  over the wireless communication field  410  to data port  420  in the generator “G”. The generator “G” then operates in the mode selected by the operator. The mode may be continuously on, selectably on, cut, seal, ablate, or coagulate. For example, the generator “G” may provide a RF field  200  with a pulsed waveform, when the surgeon is sealing tissue with the device  10 . Alternatively, the generator “G” generates the RF Field  200 , and the power circuitry  440  conditions an RF signal from the inductor  150  into a pulsed waveform for sealing tissue. The wireless communication board  460  replaces the signal wires needed in the prior art to communicate with the generator “G”. The wireless communication circuitry  460  may include a battery (not shown) to allow the wireless communication circuitry to send a signal to the generator “G” before the generator “G” generates the RF field  200  that induces power in the inductive power circuitry  440 . 
         [0040]    With reference to  FIGS. 5A and 5B , an illustrative embodiment of a wireless electrosurgical apparatus, e.g., a bipolar forceps  510  (forceps  510 ) is shown. Forceps  510  is wirelessly connected to electrosurgical generator “G” through RF field  200  for performing an electrosurgical procedure. The electrosurgical procedure may include sealing, cutting, cauterizing coagulating, desiccating, and fulgurating tissue all of which may employ RF energy. The electrosurgical generator “G” may be configured for monopolar and/or bipolar modes of operation and may include or be in operative communication with a system (not shown) that may include one or more processors in operative communication with one or more control modules that are executable on the processor. The control module (not explicitly shown) may be configured to instruct one or more modules to transmit electrosurgical energy, which may be in the form of a wave or signal/pulse to the forceps  10 . 
         [0041]    Forceps  510  is shown configured for use with various electrosurgical procedures and generally includes a housing  520 , a rotating assembly  580  and a trigger assembly  570 . For a more detailed description of the rotating assembly  80 , trigger assembly  570 , reference is made to commonly-owned U.S. patent application Ser. No. 11/595,194 filed on Nov. 9, 2006, now U.S. Patent Publication No. 2007/0173814. 
         [0042]    With continued reference to  FIGS. 5A and 5B , forceps  510  includes a shaft  512  that has a distal end  514  configured to mechanically engage an end effector assembly  590  operably associated with the forceps  510  and a proximal end  516  that mechanically engages the housing  520 . In the drawings and in the descriptions that follow, the term “proximal,” as is traditional, will refer to the end of the forceps  510  which is closer to the user, while the term “distal” will refer to the end that is farther from the user. 
         [0043]    Handle assembly  530  includes a fixed handle  550  and movable handle  540 . In one particular embodiment, fixed handle  550  is integrally associated with housing  520  and handle  540  is movable relative to fixed handle  550  for effecting movement of one or more components, e.g., a drive wire  533 , operably associated with a drive assembly  534  ( FIG. 5B ) via one or more suitable mechanical interfaces, e.g., a linkage interface, gear interface, or combination thereof. 
         [0044]    Drive assembly  534  is in operative communication with handle assembly  530  (see  FIGS. 5A and 5B ) for imparting movement of one or both of a pair of jaw members  525 ,  535  of end effector assembly  590 . The drive assembly  534  may include a compression spring (not shown) or a drive wire  533  to facilitate closing the jaw members  525  and  535 . Drive wire  533  is configured such that proximal movement thereof causes the movable jaw member, e.g., jaw member  535 , and operative components associated therewith, e.g., a seal plate  528 , to “flex” or “bend” inwardly substantially across a length thereof toward the non-movable jaw member, e.g., jaw member  525 . With this purpose in mind, drive rod or wire  533  may be made from any suitable material and is proportioned to translate within the shaft  512 . In the illustrated embodiments, drive wire  533  extends through the shaft  512  past the distal end  514 , see  FIG. 5A  for example. 
         [0045]      FIG. 6  is a flow diagram of process  600  for operating a device, such as  100  or  510 , within a wireless RF system. The process  600  starts at step  605 , with an operator pressing a switch, such as  124   a - 124   c  or  570 , on the handheld device  100  or  510  to select a mode of operation at step  610 . An instruction specifying the mode of operation is sent to the generator “G” from the wireless communication board “W” to generate the RF energy field  200  according to the specified mode of operation at step  620 . The generator “G” generates the RF field at step  630  using inductor  160 . The RF field  200  induces, in step  640 , a current to flow across inductor  150 . The power board “P” conditions the RF signal produced from inductor  150  based on the requested operational mode at step  645 . The power board “P” then supplies the RF signal to the electrode, seal plate, or other end effector assembly at step  650 . When the operator completes the procedure, the operator depresses the switch, such as  124   a - 124   c  or  570 , on the hand held device at step  660 . The process ends at step  680 , when the generator “G” receives and executes an instruction sent from the wireless communication board “W” instructing the generator “G” to stop generating the RF field  200  at step  670 . 
         [0046]    While several embodiments 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. Therefore, the above description should not be construed as limiting, but merely as exemplifications of particular embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.

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