Patent Application
20180333194
This disclosure relates to swivel instruments with flex circuits. More particularly, the disclosure relates to swivel components and flex circuits for communicating electrical signals thereacross.
As is known to those skilled in the art, modern surgical techniques typically employ radio frequency (RF) power to cut tissue and coagulate bleeding encountered in performing surgical procedures. Such electrosurgery is widely used and offers many advantages including the use of a single surgical instrument for both cutting and coagulation. A monopolar electrosurgical generator system has an active electrode, such as in the form of an electrosurgical instrument having a hand piece and a conductive electrode or tip, which is applied by the surgeon to the patient at the surgical site to perform surgery and a return electrode to connect the patient back to the generator.
The electrode or tip of the electrosurgical instrument is small at the point of contact with the patient to produce an RF current with a high current density in order to produce a surgical effect of cutting or coagulating tissue. The return electrode carries the same RF signal provided to the electrode or tip of the electrosurgical instrument, after it passes through the patient, thus providing a path back to the electrosurgical generator. To make the electrical connection for the RF current between the electrosurgical generator and the electrosurgical instrument, a cable having an electrically conductive core typically extends from the electrosurgical generator to the electrosurgical instrument.
Electrosurgical procedures often require precise movement and control of the electrosurgical instrument in order to properly treat the targeted tissue with the electrosurgical instrument. In particular, the manner in which the electrode tip is oriented and positioned relative to the targeted tissue can affect the way in which the tissue interacts with the delivered electrical energy.
In some instances, an operator may desire to readjust or reorient an electrosurgical instrument relative to the targeted tissue during an electrosurgical procedure. Using a typical electrosurgical instrument, such adjustments can increase the procedure time and typically require an operator to readjust his/her grip on the instrument, thereby increasing the risk of accidental contact between the instrument and non-targeted patient tissues.
In addition, moving and reorienting the electrosurgical instrument during a procedure typically requires moving the attached power cable and/or other hoses/connections as well. This leads to changes in the drag, torque, and torsional moment force distribution at the electrosurgical instrument, thereby altering the manner in which the instrument sits in the user's hand, making the instrument more difficult to consistently manipulate and control, and further increasing the risk of accident or procedural mistakes.
Further, changes in the way in which the instrument needs to be held or gripped as well as changes to the force distributions of the instrument against a user's hand can reduce user comfort during use of the instrument and can lead to faster hand fatigue.
The subject matter claimed herein is not limited to embodiments that solve any disadvantages or that operate only in environments such as those described above. Rather, this background is only provided to illustrate one exemplary technology area where some embodiments described herein may be practiced.
The present disclosure addresses at least some of the foregoing shortcomings by providing an electrical instrument that has swivel or rotational capabilities. For instance, in some embodiments, an electrical instrument includes a proximal section; a distal section, and a flex circuit. The distal section can be coupled to the proximal section at a swivel interface to enable rotational independence of the distal section relative to the proximal section. The flex circuit can span the swivel interface between the proximal section and the distal section. Additionally, the flex circuit can be configured to provide electrical communication between the proximal section and the distal section even when one of the proximal section and the distal section is rotated relative to the other.
According to other exemplary embodiments, a hand-held electrical instrument includes rotational capabilities. The instrument includes a hand piece, a swivel interface, a functional implement, and a flex circuit. The hand piece has a proximal section and a distal section, with the proximal section being configured to have one or more electrical cables connected thereto to communicate electrical signals or electrical energy to or from the instrument. The distal section has one or more user activated controls. The swivel interface is between the proximal section and the distal section, and includes a channeled section and a radial extension that extends into the channeled section to couple the proximal section and distal section together while enabling rotational independence of the distal section relative to the proximal section. The functional implement is associated with the distal section and is rotationally linked with the distal section such that rotation of the distal section results in corresponding rotation of the functional implement. The flex circuit spans the swivel interface between the proximal section and the distal section and is configured to provide electrical communication between the proximal section and the distal section even when one of the proximal section and the distal section is rotated relative to the other.
In other exemplary embodiments, a flex circuit includes a substrate having a top surface and a bottom surface, and a first trace, a second trace, and a third trace disposed on the substrate. The first trace, the second trace, and the third trace are electrically insulated from one another. Additionally, the flex circuit is arranged in a plurality of identifiable sections, including a first linear section, a second linear section, and a serpentine section that is disposed between the first linear section and the second linear section. The serpentine section enables the flex circuit to flex, twist, expand, or contract while maintaining electrical communication between the first linear section and the second linear section.
This Summary is provided to introduce a selection of concepts in a simplified form that are further described below in the Detailed Description. This Summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used as an aid in determining the scope of the claimed subject matter.
Additional features and advantages of the disclosed embodiments will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by the practice of the disclosure. These and other features will become more fully apparent from the following description and appended claims, or may be learned by the practice of the present disclosure.
To further clarify the above and other advantages and features of the present invention, a more particular description of the invention will be rendered by reference to specific embodiments thereof which are illustrated in the appended drawings. It is appreciated that these drawings depict only illustrated embodiments of the invention and are therefore not to be considered limiting of its scope. The invention will be described and explained with additional specificity and detail through the use of the accompanying drawings in which:
The present disclosure relates to instruments that include a first portion and a second portion that are able to swivel relative to one another and that include a flex circuit for communicating electrical signals across the first and second portions even when the first and second portions swivel. The swivel capabilities of the instruments enables precise control and fine adjustment of the instrument during a procedure, such as during an electrosurgical procedure. The flex circuit enables the first and second portions to rotate or swivel relative to one another with minimal resistance.
In some embodiments, the instrument takes the form of an electrosurgical or other hand-held instrument that includes a hand piece. The hand piece can include a proximal section and a distal section that correspond to the first and second portions, such that the proximal section and the distal section are rotationally decoupled to enable the distal section to be rotated independently of the proximal section, or vice versa. The flex circuit enables electrical signals to be communicated from controls on the distal section, through the proximal section, and to an electrosurgical generator, even when the proximal and distal sections are rotated relative to one another. Likewise, the flex circuit enables communication of RF current from an electrical generator to pass into the proximal section, through the proximal section, into the distal section, and to an electrode mounted in the distal section, even when the proximal and distal sections are rotated relative to one another.
In hand-held embodiments, the swivel and flex circuit features beneficially enable the instrument to be manipulated and reoriented without disrupting the grip position of the instrument in a user's hand. For example, during an electrosurgical procedure, a user may hold a hand piece by positioning the proximal section of the hand piece in the crook of his/her hand while gripping the distal section of the hand piece between the thumb and index and/or middle finger. The instrument enables the user to independently rotate the distal section relative to the proximal section, allowing the thumb and/or fingers to control the rotational manipulation of the distal section while the proximal section remains seated in the crook of the hand. The flex circuit is configured and arranged in the hand piece such that the flex circuit creates minimal or limited resistance to the rotation of the distal section while still maintaining electrical communication between the proximal and distal sections of the hand piece.
Alternatively, a user may hold the hand piece by gripping the distal section with the thumb and fingers and allow the proximal section to rotate relative to the distal section, even if the proximal section is in contact with the user's hand. As a result, cords and/or tubing connected to the proximal section, which may cause the proximal section to rotate as the hand piece is moved, will not force the distal section to rotate because the proximal and distal sections are rotationally decoupled from one another. Again, the flex circuit also creates minimal or limited resistance to the rotation of the proximal section while still maintaining electrical communication between the proximal and distal sections of the hand piece.
The structure and function of such embodiments can allow a user to adjust the instrument while minimizing or reducing changes in the force distribution (e.g., torque and drag effects) on the user's hand or requiring excessive force to rotate the distal section relative to the proximal section. Such benefits reduce or eliminate operator discomfort and fatigue, allow more consistent tissue/electrode interfacing, improve user flexibility in following a cutting line or plane, improve precision movement and positioning for both cutting and coagulation, and help maintain consistent grip dynamics, thereby reducing or eliminating associated patient and equipment risks, which result in better, more successful surgical outcomes. The flex circuit is also configured to allow for the noted rotation while limiting or preventing internal components of the hand piece from being tangled, overstretched, twisted, or otherwise disordered in a manner that would interrupt electrical communication or inhibit free rotation of the hand piece sections.
Generally, electrosurgical instrument 104 includes a hand piece or pencil 114 and an electrode tip 116. Electrosurgical instrument 104 communicates electrical energy to a target tissue of a patient to cut the tissue and/or cauterize blood vessels within and/or near the target tissue. Specifically, an electrical discharge is delivered from electrode tip 116 to the patient in order to cause heating of cellular matter of the patient that is in close contact with electrode tip 116. The tissue heating takes place at an appropriately high temperature to allow electrosurgical instrument 104 to be used to perform electrosurgery. Return electrode 106 is connected to generator 102 by a cable 118, and is either applied to or placed in near contact with the patient (depending on the type of return electrode), in order to complete the circuit and provide a return electrical path to wave generator 102 for energy that passes into the patient's body.
Illustrated in
Electrosurgical instruments, such as electrosurgical instrument 120, are commonly referred to as electrosurgical pencils or pens because in use they are often held in the same manner that a pencil or pen is held when writing.
The one or more controls 136 enable a user to adjust one or more parameters of the electrosurgical instrument 120, such as increasing or decreasing electrical power delivery through the instrument, turning the instrument on and off, adjusting the instrument for different operating modes (cut, coagulate, cut-coagulate blend), etc. For example, the controls 136 can provide a connection for transmitting control signals from the electrosurgical instrument 120 to an electrosurgical generator and/or other controller.
The embodiment shown in
On the other hand, by rotating the electrode tip 130 relative to the targeted tissue to position the blunt edge 146 or one of the side faces 148 of the electrode tip 130, which has a relatively higher surface area, near the targeted tissue, the density of the current passing from the electrode tip 130 to the targeted tissue is distributed across a greater area and is relatively lower (e.g., for use in a more dispersed spray-type coagulation mode or large area contact coagulation). Rotation of the electrode tip 130 can therefore allow a user to perform different types of procedures and/or to dynamically adjust the operation of the electrosurgical instrument 120 during an electrosurgical procedure (e.g., by adjusting the level of pinpoint-type operation relative to spray-type operation and vice versa).
For example, during an electrosurgical procedure, a user can rotate the distal section 126 to alter the orientation of the electrode tip 130 relative to a targeted tissue. This can beneficially enable a user to dynamically adjust the operational characteristics of the electrosurgical instrument, such as by altering the angle at which the electrode tip 130 interacts with the tissue (e.g., by adjusting which portion of the electrode is brought nearest the tissue). For example, the user can rotate the distal section 126 to angle the electrode edge nearer or farther from the target tissue, according to the user's preferences and/or patient needs. In addition, the electrosurgical instrument 120 allows a user to make dynamic adjustments during a procedure, such as by rotating the distal section 126 to adjust the angle of the electrode tip 130 to account for changing tissue geometries (e.g., curves, bumps, etc.) or tissue types (e.g., fat, muscle, skin, nerves, blood vessels, organs, etc.) along a cutting or treatment path.
In a typical manner in which the hand piece 122 is held (see
The hand piece 122 may also be configured to allow the user to hold the distal section 126 (e.g., between the user's thumb and middle finger and/or index finger) in a desired orientation, while allowing the proximal section 124 to rotate relative to the distal section 126. For instance, as noted above, the proximal section 124 may have a utility conduit 140, hose, or cable connected thereto. As the user moves the hand piece 122 (or the distal section 126 thereof), the utility conduit 140, hose, or cable may resist the movement of the hand piece 122. As discussed herein, such resistance can be undesirable for various reasons. By rotationally decoupling the proximal section 124 from the distal section 126, the proximal section 124 is able to rotate relative to the distal section 126 in response to the resistance from the utility conduit 140, hose, or cable. Thus, while the resistance from the utility conduit 140, hose, or cable may cause the proximal section to rotate, the user may maintain the distal section 126 in a desired orientation.
Further, by joining the utility conduit 140 to the proximal section 124, rotational movement of the distal section 126 is mechanically decoupled from the utility conduit 140, allowing rotational adjustments to be made without changing the force distribution on the hand piece 122 and without altering the drag, torque, or torsional moment forces resulting from connection of the utility conduit 140. This further allows the user's grip position to be maintained and provides more consistent controllability of the electrosurgical instrument 120 by keeping drag, torque, torsional moment forces, and other forces applied to the user's hand consistent throughout a procedure. For example, the utility conduit 140 can aid in anchoring the hand piece 122 in the user's hand in a stable manner, and by decoupling rotation of the distal section 126 from the proximal section 124 and utility conduit 140, this stable anchoring function can be maintained without swivel-induced fluctuation or change.
The illustrated attachment piece 150 is formed as a ring having a channeled section 152 and a rim 154 disposed proximal to the channeled section. The structure of the attachment piece 150 allows components of the instrument to be passed from the distal section 126 to the proximal section 124, and vice versa, through the opening of the ring structure. For example, this allows a flex circuit 160 (discussed in greater detail below) to be disposed within the interiors of both the distal section 126 and the proximal section 124 and extend therebetween.
In the illustrated embodiments, the channeled section 152 of the attachment piece 150 is disposed between the rim 154 and a proximal edge 162 of the distal section 126. As shown, the rim 154 and the proximal edge 162 of the distal section 126 have diameters that are larger than the diameter of the attachment piece 150 at the channeled section 152. This enables the proximal section 124 to be linked to the distal section 126 through insertion of an inward radial extension 164 (disposed at the distal edge of the proximal section 124) into the channeled section 152 of the attachment piece 150, placing the extension 164 between the rim 154 and the proximal edge 162 of the distal section 126. Proximal or distal separation of the distal section 126 from the proximal section 124 is therefore prevented, while independent rotational movement of the distal section 126 relative to the proximal section 124 is maintained.
In the illustrated embodiment, the attachment piece 150 also includes a catch 166 projecting further proximally relative to the remaining proximal surface of the attachment piece 150. The proximal section 124 also includes a swivel stop 168 disposed at or near the proximal surface of the attachment piece 150. Rotation of the distal section 126 causes the attachment piece 150 to correspondingly rotate. Rotation can be continued until the catch 166 abuts against the swivel stop 168. The range of rotation can therefore be limited according to the position of the catch 166 and/or swivel stop 168.
Other embodiments omit swivel-limiting means, allowing a full 360 degree rotation of the distal section 126 relative to the proximal section 124. In some embodiments, rotation is limited to a range of about 45 to 315 degrees, or about 60 to 300 degrees, or about 90 to 270 degrees, for example.
In the embodiment illustrated in
In some embodiments, the electrode tip 130 may be mounted or otherwise associated with the hand piece 122 such that there is a fixed relationship between the electrode tip 130 and at least a portion of the hand piece 122. For instance, the orientation of the electrode tip 130 may be fixed relative to the distal section 126 (e.g., such that blunt edge 146 is aligned with and faces the same direction as controls 136). In other embodiments, however, electrode tip 130 may be adjustably mounted or otherwise associated with hand piece 122. For instance, the orientation of the electrode tip 130 may be selectively adjusted relative to one or more portions of the hand piece 122. By way of example, the electrode tip 130 may be mounted in the hand piece 122 with the blunt edge 146 facing in various directions (e.g., such that blunt edge 146 is not aligned with or facing in the same direction as controls 136). The electrode tip 130 may also be mounted such that the electrode tip 130 extends a fixed or variable distance from hand piece 122.
The illustrated embodiment provides a smooth interface between the channeled section 152 and the extension 164, allowing free rotation of the distal section 126 throughout the range of rotation. In other embodiments, rotation may be confined to discrete positions (e.g., in increments of 5, 10, 15, 20, 25, 30, 45, 60 degrees), such as by forming the grooved or sectioned interface between the channeled section 152 and the extension 164.
With continued attention to
A third trace 190 is disposed on a bottom surface of the substrate 184, as shown in
While the illustrated embodiment of the flex circuit includes three traces, with two traces on a first side and a single trace on a second side, this is merely exemplary. In other embodiments, a flex circuit may have fewer or more than three traces. Furthermore, the trace(s) may be disposed on a single side of the flex circuit or on multiple sides thereof. Still further, a flex circuit according to the present disclosure may include multiple layers. One or more traces may be disposed on one or more of the multiple layers. The traces may provide for additional communication or functionality for the hand piece.
The flex circuit 160 is configured to allow for the distal section 126 to rotate or swivel relative to the proximal section 124 (or vice versa) even when the distal and proximal ends 180, 182 of the flex circuit 160 are (fixedly) connected to or within the distal and proximal sections 126, 124, respectively. As illustrated in
As can be seen, the serpentine section 202 is disposed between the first and second linear sections 200, 204. The first linear section 200 is long enough to extend proximally from adjacent the controls 136 to the interior of the proximal section 124 of the hand piece 122, as can be seen in
In some embodiments, including the embodiments illustrated in
The offset between the first linear section 200 and the second linear section 204 can enable connection of the distal and proximal end 180, 182 of the flex circuit 160 to the desired locations. For instance, when the hand piece 122 is in a neutral position (e.g. distal section 126 is not rotated relative to proximal section 124, as shown in
The serpentine section 202 includes a plurality of legs 206 and bends 208 connecting the legs 206 and the first and second linear sections 200, 204. As can be seen in
In some embodiments, when the legs 206 and bends 208 flex, ends of adjacent legs 206 may spread apart or move closer together. Likewise, adjacent bends 208 may spread apart or move closer together. Such movements of the legs 206 and bends 208 can effectively lengthen the flex circuit 160 when the proximal and distal sections 124, 126 are rotated relative to one another. The configuration of the legs 206 and bends 208 allows the flex circuit 160 to twist in either direction and return to a resting state (e.g., as shown in
While the present embodiments are illustrated with a specific number of legs 206 and bends 208, it will be appreciated that a flex circuit may include fewer or more legs and/or bends. Including fewer or more legs and/or bends may allow the flex circuit to flex, twist, expand, or contract a desired amount for a particular application. For instance, including fewer bends and legs may be suitable when relative rotation between the proximal and distal sections of the device is limited. In contrast, more bends and legs may be included in a flex circuit used in a device with a greater degree of available rotation between proximal and distal sections.
While the legs 206 in the embodiment illustrated in
In the embodiment illustrated in
It will be appreciated that the illustrated flex circuit is only one example embodiment. A flex circuit according to the present disclosure may take various forms or include various modifications. For instance, while the bends 208 are illustrated as directly connecting adjacent legs 206, in other embodiments, bends may include straight sections that further space apart the adjacent legs from one another.
In other embodiments, such as that shown in
While the previous embodiments have shown adjacent legs forming acute angles, it will be appreciated that some embodiments include adjacent legs which form obtuse angles. Furthermore, some legs may form acute angles while other legs form obtuse angles. Still further, the lengths of the legs may be equal to one another, or the lengths may vary, or the lengths of some legs may be equal while the lengths of other legs may vary.
While the embodiments described herein have been directed to electrosurgical instruments, the present disclosure is not intended to be so limited. Rather, the present disclosure is broadly directed to any instrument that includes first and second portions, at least one of which swivels or rotates relative to the other, and a flex circuit extending between the first and second portions such that the flex circuit enables electrical communication across the swivel connection between the first and second portions. Thus, for instance, such an instrument may include a surgical instrument connectable to a robotic surgical arm. Such instruments may also be used in non-electrosurgical environments. In such cases, the instrument may include a functional implement other than an electrode tip for performing a desired function. Thus, reference herein to an electrode tip or tip is not limited to implements used to perform electrosurgical procedures. Rather, reference to an electrode tip or tip is intended to broadly refer to any functional implement that is or can be associated with an instrument and which is usable to perform a desired function.
By way of non-limiting example, instruments according to the present disclosure may include surgical robot attachments, dental instruments (e.g., drills, polishing tools, scalers, compressed air tools, suction tools, irrigation tools, carries detection tools, water flossing tools (e.g., waterpik)), soldering tools (e.g., heated tools, smoke collection tools, de-soldering tools), high speed grinding and polishing tools (e.g., Dremel tools, carving tools, manicure tools, dental lab grinders/polishers), laser treatment instruments, laser surgical instruments, light probes, suction handles (e.g., Yankauer), blasting tools (e.g., sandblast, gritblast), shockwave therapy tools, ultrasonic therapy tools, ultrasonic probe tools, ultrasonic surgical tools, adhesive application instruments, glue guns, pneumatic pipettes, welding tools, RF wrinkle therapy hand pieces, phaco hand pieces, shears, shaver, or razor hand pieces, micro drill hand pieces, vacuum hand pieces, small parts handling hand pieces, tattoo needle handles, small torch hand pieces, electrology hand pieces, low speed grinding, polishing and carving tools, permanent makeup hand pieces, electrical probe hand pieces, ferromagnetic surgical hand pieces, surgical plasma hand pieces, argon beam surgical hand pieces, surgical laser hand pieces, surgical suction instruments (e.g., liposuction cannulas), surgical suction cannulas, microdermabrasion hand pieces, fiberoptic camera handles, microcamera hand pieces, pH probe hand pieces, fiberoptic and LED light source hand pieces, hydrosurgery hand pieces, orthopedic shaver, cutter, burr hand pieces, wood burning tools, electric screwdrivers, electronic pad styluses, and the like.
The present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The described embodiments are to be considered in all respects only as illustrative and not restrictive. The scope of the invention is, therefore, indicated by the appended claims rather than by the foregoing description. All changes which come within the meaning and range of equivalency of the claims are to be embraced within their scope.
