US20030014053A1 - Vessel sealing instrument - Google Patents

Abstract

A bipolar electrosurgical instrument for clamping, grasping, manipulating, and sealing tissue includes first and second shafts each having a jaw member extending from a distal end thereof and a handle disposed at a proximal end thereof. The handle being operable to effect movement of the jaw members relative to one another from a first position wherein the jaw members are disposed in spaced relation relative to one another to a second position wherein the jaw members cooperate to grasp tissue therebetween. The bipolar instrument is connectable to a source of electrical energy having a first electrical potential connected to one of the jaw members and a second electrical potential connected to the other of the jaw members such that the jaw members are capable of selectively conducting energy through tissue held therebetween to effect a seal. Both the first and second electrical potentials are transmitted to the jaw members through the first shaft.

Description

CROSS REFERENCE TO RELATED APPLICATIONS
• This application is a continuation-in-part of PCT Application Serial No. PCT/US01/11420 filed on Apr. 6, 2001 which is a continuation-in-part of U.S. application Ser. No. 09/425,696 filed Oct. 22, 1999 by Philip Mark Tetzlaff et al. which is a continuation-in-part of U.S. application Ser. No. 09/178,027 filed Oct. 23, 1998 by Philip Mark Tetzlaff et al., the entire contents of each of these applications are hereby incorporated by reference.[0001]
BACKGROUND
• The present disclosure relates to forceps used for open surgical procedures. More particularly, the present disclosure relates to a forceps which applies a combination of mechanical clamping pressure and electrosurgical current to seal tissue.[0002]
TECHNICAL FIELD
• A hemostat or forceps is a simple plier-like tool which uses mechanical action between its jaws to constrict vessels and is commonly used in open surgical procedures to grasp, dissect and/or clamp tissue. Electrosurgical forceps utilize both mechanical clamping action and electrical energy to effect hemostasis by heating the tissue and blood vessels to coagulate, cauterize and/or seal tissue.[0003]
• Certain surgical procedures require sealing and cutting blood vessels or vascular tissue. Several journal articles have disclosed methods for sealing small blood vessels using electrosurgery. An article entitled[0004]Studies on Coagulation and the Development of an Automatic Computerized Bipolar Coagulator,J. Neurosurg.,Volume 75, July 1991, describes a bipolar coagulator which is used to seal small blood vessels. The article states that it is not possible to safely coagulate arteries with a diameter larger than 2 to 2.5 mm. A second article is entitledAutomatically Controlled Bipolar Electrocoagulation—“COA-COMP”, Neurosurg. Rev. (1984), pp. 187-190, describes a method for terminating electrosurgical power to the vessel so that charring of the vessel walls can be avoided.
• By utilizing an electrosurgical forceps, a surgeon can either cauterize, coagulate/desiccate, reduce or slow bleeding and/or seal vessels by controlling the intensity, frequency and duration of the electrosurgical energy applied to the tissue. Generally, the electrical configuration of electrosurgical forceps can be categorized in two classifications: 1) monopolar electrosurgical forceps; and 2) bipolar electrosurgical forceps.[0005]
• Monopolar forceps utilize one active electrode associated with the clamping end effector and a remote patient return electrode or pad which is typically attached externally to the patient. When the electrosurgical energy is applied, the energy travels from the active electrode, to the surgical site, through the patient and to the return electrode.[0006]
• Bipolar electrosurgical forceps utilize two generally opposing electrodes which are disposed on the inner opposing surfaces of the end effectors and which are both electrically coupled to an electrosurgical generator. Each electrode is charged to a different electric potential. Since tissue is a conductor of electrical energy, when the effectors are utilized to grasp tissue therebetween, the electrical energy can be selectively transferred through the tissue.[0007]
• In order to effect a proper seal with larger vessels, two predominant mechanical parameters must be accurately controlled—the pressure applied to the vessel and the gap between the electrodes both of which affect thickness of the sealed vessel. More particularly, accurate application of the pressure is important to oppose the walls of the vessel, to reduce the tissue impedance to a low enough value that allows enough electrosurgical energy through the tissue, to overcome the forces of expansion during tissue heating and to contribute to the end tissue thickness which is an indication of a good seal. It has been determined that a fused vessel wall is optimum between 0.001 and 0.005 inches. Below this range, the seal may shred or tear and above this range the lumens may not be properly or effectively sealed.[0008]
• With respect to smaller vessel, the pressure applied to the tissue tends to become less relevant whereas the gap distance between the electrically conductive surfaces becomes more significant for effective sealing. In other words, the chances of the two electrically conductive surfaces touching during activation increases as the vessels become smaller.[0009]
• Electrosurgical methods may be able to seal larger vessels using an appropriate electrosurgical power curve, coupled with an instrument capable of applying a large closure force to the vessel walls. It is thought that the process of coagulating small vessels is fundamentally different than electrosurgical vessel sealing. For the purposes herein, “coagulation” is defined as a process of desiccating tissue wherein the tissue cells are ruptured and dried and vessel sealing is defined as the process of liquefying the collagen in the tissue so that it reforms into a fused mass. Thus, coagulation of small vessels is sufficient to permanently close them. Larger vessels need to be sealed to assure permanent closure.[0010]
• Numerous bipolar electrosurgical forceps have been proposed in the past for various open surgical procedures. However, some of these designs may not provide uniformly reproducible pressure to the blood vessel and may result in an ineffective or non-uniform seal. For example, U.S. Pat. No. 2,176,479 to Willis, U.S. Pat. Nos. 4,005,714 and 4,031,898 to Hiltebrandt, U.S. Pat. Nos. 5,827,274, 5,290,287 and 5,312,433 to Boebel et al., U.S. Pat. Nos. 4,370,980, 4,552,143, 5,026,370 and 5,116,332 to Lottick, U.S. Pat. No. 5,443,463 to Stern et al., U.S. Pat. No. 5,484,436 to Eggers et al. and U.S. Pat. No. 5,951,549 to Richardson et al., all relate to electrosurgical instruments for coagulating, cutting and/or sealing vessels or tissue.[0011]
• Many of these instruments include blade members or shearing members which simply cut tissue in a mechanical and/or electromechanical manner and are relatively ineffective for vessel sealing purposes. Other instruments rely on clamping pressure alone to procure proper sealing thickness and are not designed to take into account gap tolerances and/or parallelism and flatness requirements which are parameters which, if properly controlled, can assure a consistent and effective tissue seal. For example, it is known that it is difficult to adequately control thickness of the resulting sealed tissue by controlling clamping pressure alone for either of two reasons: 1) if too much force is applied, there is a possibility that the two poles will touch and energy will not be transferred through the tissue resulting in an ineffective seal; or 2) if too low a force is applied, a thicker less reliable seal is created.[0012]
• As mentioned above, in order to properly and effectively seal larger vessels, a greater closure force between opposing jaw members is required. It is known that a large closure force between the jaws typically requires a large moment about the pivot for each jaw. This presents a challenge because the jaw members are typically affixed with pins which are positioned to have a small moment arms with respect to the pivot of each jaw member. A large force, coupled with a small moment arm, is undesirable because the large forces may shear the pins. As a result, designers must compensate for these large closure forces by either designing instruments with metal pins and/or by designing instruments which at least partially offload these closure forces to reduce the chances of mechanical failure. As can be appreciated, if metal pivot pins are employed, the metal pins must be insulated to avoid the pin acting as an alternate current path between the jaw members which may prove detrimental to effective sealing.[0013]
• Increasing the closure forces between electrodes may have other undesirable effects, e.g., it may cause the opposing electrodes to come into close contact with one another which may result in a short circuit and a small closure force may cause pre-mature movement of the issue during compression and prior to activation.[0014]
• Thus, a need exists to develop a bipolar forceps which effectively seals vascular tissue and solves the aforementioned problems by providing an instrument which enables a large closure force between the opposing jaws members, reduces the chances of short circuiting the opposing jaws during activation and assists in manipulating, gripping and holding the tissue prior to and during activation.[0015]
SUMMARY
• The present disclosure relates to a bipolar electrosurgical instrument for use in open surgery which includes first and second shafts one of which is connectable to a source of electrosurgical energy. Each shaft includes a jaw member extending from a distal end thereof and a handle disposed at a proximal end thereof for effecting movement of the jaw members relative to one another from a first, open position wherein the jaw members are disposed in spaced relation relative to one another to a second, closed position wherein the jaw members cooperate to grasp tissue therebetween. The source of electrical energy effects first and second electrical potentials in the respective jaw members such that the jaw members are capable of selectively conducting energy through tissue held therebetween to effect a seal.[0016]
• Preferably, the first and second electrical potentials are created at the jaw members through the first shaft. For example, in one embodiment, the first electrical potential is transmitted through the first shaft by a lead having a terminal end which electrically interfaces with a distal connector which connects a first jaw member to the first electrical potential. The second electrical potential is transmitted through the first shaft by a tube disposed within the first shaft which connects the second jaw member to the second electrical potential.[0017]
• The first and second jaw members are connected about a pivot pin. The distal connector is preferably interposed between the jaw members and includes a series of flanges which are dimensioned to prevent the emanation of stray currents from the electrically conductive sealing surfaces of the jaw members during activation.[0018]
• Preferably, the distal connector includes a spring washer or wave washer which acts as an electrical intermediary between the terminal end and the jaw member. In one embodiment, the spring washer is beveled to enhance the electrical interface between the terminal end and the jaw member, i.e., beveling causes the spring washer to rotate relative the terminal end during movement of the jaw members from the first to second positions which provides a self-cleaning, enhanced running electrical contact between the terminal end and the jaw member.[0019]
• Preferably, the distal connector is made from an insulative substrate and is disposed between the jaw members for electrically isolating the first and second potentials. In one embodiment, the distal connector includes a first surface having at least one recess defined therein which is dimensioned to receive at least a portion of the terminal end of the lead.[0020]
• In yet another embodiment, one of the jaw members includes a skirt which is dimensioned to prevent exposure of the terminal end during all angles of operation, i.e., when the jaw members are disposed in the first position, the second position and/or during operative movement therebetween.[0021]
• The lead preferably includes a inner core made from a solid or multi-strand electrically conductive material, e.g., copper/aluminum wire, which is surrounded by an insulative, non-conductive coating, e.g., plastic. In one embodiment, the terminal or distal end of the electrically conductive material is flattened, i.e., “flat-formed”, and is dimensioned to substantially encircle a boss which extends from the surface of the distal connector. Preferably, the boss is designed to electrically insulate the terminal end of the lead from the pivot pin.[0022]
• In another embodiment, at least one non-conductive stop member is disposed on an electrically conductive sealing surface of one of the jaw members. The stop members are designed to control/regulate the distance, i.e., gap, between the jaw members when tissue is held therebetween during activation.[0023]
BRIEF DESCRIPTION OF THE DRAWINGS
• Various embodiments of the subject instrument are described herein with reference to the drawings wherein:[0024]
• FIG. 1 is a left, perspective view of a forceps according to the present disclosure;[0025]
• FIG. 2 is an enlarged, perspective view of an end effector assembly of the forceps of FIG. 1 shown in open configuration;[0026]
• FIG. 2′ is an enlarged view of the distal end of a bipolar instrument incorporated by reference from a prior disclosure;[0027]
• FIG. 3 is an enlarged, perspective view of the end effector assembly of the forceps of FIG. 1 shown in closed configuration;[0028]
• FIG. 4A is an exploded view of the forceps according to the present disclosure;[0029]
• FIG. 4B is an enlarged, exploded view of the end effector assembly of FIG. 4A showing the electrical connection of a distal electrical connector for supplying electrical energy to the end effector assembly;[0030]
• FIG. 4′ is an enlarged, exploded view of the end effector assembly of a bipolar instrument incorporated by reference from a prior disclosure;[0031]
• FIG. 5 is an enlarged, top perspective view of a lower jaw member of forceps with the distal connector seated thereon;[0032]
• FIG. 5′ is an enlarged view of a distal end of a bipolar instrument incorporated by reference from a prior disclosure;[0033]
• FIG. 6 is a right, perspective view of the forceps of FIG. 1 shown grasping a tissue structure;[0034]
• FIG. 6A′-[0035]6G′ are enlarged views of jaw members and stop configurations of a bipolar instrument incorporated by reference from a prior disclosure;
• FIG. 7 is a enlarged view of the indicated area of detail in FIG. 4A showing a proximal electrical interface/connector for supplying electrical energy to the end effector assembly; and[0036]
• FIG. 8 is a cross section of the forceps of FIG. 6 showing the electrical feed path of a first lead having a first electrical potential and showing the electrical connection of the proximal electrical interface of FIG. 7 with a second lead having a second electrical potential.[0037]
DETAILED DESCRIPTION
• Referring now to FIGS.[0038]1-4, aforceps10 for use with open surgical procedures includeselongated shaft portions12aand12beach having aproximal end16aand16b, respectively, and adistal end14aand14b, respectively. In the drawings and in the descriptions which follow, the term “proximal”, as is traditional, will refer to the end of theforceps10 which is closer to the user, while the term “distal” will refer to the end which is further from the user.
• The[0039]forceps10 includes anend effector assembly100 which attaches to distal ends14aand14bofshafts12aand12b, respectively. As explained in more detail below, theend effector assembly100 includes pair of opposingjaw members110 and120 which are pivotably connected about apivot pin150.
• Preferably, each[0040]shaft12aand12bincludes ahandle17aand17bdisposed at theproximal end16aand16bthereof which each define afinger hole18aand18b, respectively, therethrough for receiving a finger of the user. As can be appreciated, finger holes18aand18bfacilitate movement of theshafts12aand12brelative to one another which, in turn, pivot thejaw members110 and120 from an open position (FIG. 2) wherein thejaw members110 and120 are disposed in spaced relation relative to one another to a clamping or closed position (FIG. 3) wherein thejaw members110 and120 cooperate to grasp tissue400 (FIG. 6) therebetween.
• A[0041]ratchet30 is preferably included for selectively locking thejaw members110 and120 relative to one another at various positions during pivoting. As best shown in FIG. 6, a first ratchet interface, e.g.,30a, extends from theproximal end16aofshaft member12atowards asecond ratchet interface30bin a generally vertically aligned manner such that the inner facing surfaces of each ratchet30aand30babut one another upon closure about thetissue400. Preferably, eachratchet interface30aand30bincludes a plurality offlanges32aand32b, respectively, which projects from the inner facing surface of eachratchet interface30aand30bsuch that the ratchet interfaces30aand30binterlock in at least one position. In the embodiment shown in FIG. 6, the ratchet interfaces30aand30binterlock at several different positions.
• Preferably, each position associated with the cooperating ratchet interfaces[0042]30aand30bholds a specific, i.e., constant, strain energy in theshaft members12aand12bwhich, in turn, transmits a specific closing force to thejaw members110 and120. It is envisioned that theratchet30 may include graduations or other visual markings which enable the user to easily and quickly ascertain and control the amount of closure force desired between the jaw members. A design without a ratchet system or similar system would require the user to hold thejaw members110 and120 together by applying constant force to thehandles17aand17bwhich may yield inconsistent results.
• As best illustrated in FIG. 1, one of the shafts, e.g.,[0043]12b, includes aproximal shaft connector19 which is designed to connect theforceps10 to a source of electrosurgical energy such as an electrosurgical generator (not shown). More particularly,proximal shaft connector19 is formed by acover19aand a flange19bwhich extends proximally fromshaft12b. Preferably, cover19aand flange19bmechanically cooperate to secure anelectrosurgical cable210 to theforceps10 such that the user may selectively apply electrosurgical energy as needed.
• The proximal end of the[0044]cable210 includes aplug200 having a pair ofprongs202aand202bwhich are dimensioned to electrically and mechanically engage the electrosurgical energy generator. As explained in more detail below with respect to FIG. 8, the distal end of thecable210 is secured to theproximal shaft connector19 ofshaft12bby a plurality of finger-like clamping members77aand77band a cable crimp having opposingfingers76aand76b. The interior ofcable210 houses a pair ofleads210aand210bwhich conduct the different electrical potentials from the electrosurgical generator to thejaw members110 and120 as explained in greater detail below.
• As best seen in FIGS.[0045]2-4B, the two opposingjaw members110 and120 of theend effector assembly100 are pivotable aboutpin150 from the open position to the closed position for graspingtissue400 therebetween.Jaw members110 and120 are generally symmetrical and include similar component features which cooperate to permit facile rotation aboutpivot pin150 to effect the grasping and sealing oftissue400. As a result and unless otherwise noted,jaw member110 and the operative features associated therewith will initially be described herein in detail and the similar component features with respect tojaw member120 will be briefly summarized thereafter.
• [0046]Jaw member110 includes an insulatedouter housing114 which is dimensioned to mechanically engage an electricallyconductive sealing surface112 and aproximally extending flange130 which is dimensioned to seat adistal connector300 which is described in more detail below with respect to FIGS. 4A, 4B and5. Preferably, outerinsulative housing114 extends along the entire length ofjaw member110 to reduce alternate or stray current paths during sealing and/or incidental burning oftissue400. The inner facing surface offlange130 includes an electrically conductive plate134 (FIG. 4B) which conducts electrosurgical energy to the electricallyconductive sealing surface112 upon activation.
• Likewise,[0047]jaw member120 include similar elements which include: anouter housing124 which engages an electricallyconductive sealing surface122; aproximally extending flange140 which seats the opposite face of thedistal connector300; an electricallyconductive plate144 which conducts electrosurgical energy to the electricallyconductive sealing surface122 upon activation.
• It is envisioned that one of the jaw members, e.g.,[0048]110, includes at least onestop member150 disposed on the inner facing surface of the electrically conductive sealing surface112 (and/or122). Alternatively or in addition, thestop member150 may be positioned adjacent to the electrically conductive sealing surfaces112,122 or proximate thepivot pin151. The stop member(s) is preferably designed to facilitate gripping and manipulation oftissue400 and to define a gap “G” (FIG. 6) between opposingjaw members110 and120 during sealing. Preferably the separation distance during sealing or the gap distance “G” is within the range of about 0.001 inches (˜0.03 millimeters) to about 0.006 inches (˜0.016 millimeters).
• A detailed discussion of these and other envisioned stop[0049]members150 as well as various manufacturing and assembling processes for attaching, disposing, depositing and/or affixing thestop members150 to the electrically conductive sealing surfaces112,122 are described in commonly-assigned, co-pending PCT Application Serial No. PCT/US01/11222 entitled “BIPOLAR ELECTROSURGICAL FORCEPS WITH NON-CONDUCTIVE STOP MEMBERS” which is hereby incorporated by reference in its entirety herein. For the purposes of this disclosure at least the following text from PCT/US01/11222 is included herein. Corresponding reference numeral to the present disclosure are enclosed between parentheses “( )” for the purposes of clarity. In addition, FIGS. 2, 4,15B and16A-16G from the above disclosure are incorporated herein and renumbered as FIGS.2′,4′,5′ and6A′-6G′ for the purposes of clarity. The reference numerals associated with these figures also include a prime “′” designation for the purposes of clarity, e.g.,80′,82′, etc.
• As mentioned above, two mechanical factors play an important role in determining the resulting thickness of the sealed tissue and effectiveness of the seal, i.e., the pressure applied between opposing[0050]jaw members80′ and82′ (110 and120) and the gap between the opposingjaw members80′ and82′ (110 and120) during the sealing process. However, thickness of the resulting tissue seal cannot be adequately controlled by force alone. In other words, too much force and the twojaw members80′ and82′ (110 and120) would touch and possibly short resulting in little energy traveling through the tissue thus resulting in a bad seal. Too little force and the seal would be too thick.
• Applying the correct force is also important for other reasons: to oppose the walls of the vessel; to reduce the tissue impedance to a low enough value that allows enough current through the tissue; and to overcome the forces of expansion during tissue heating in addition to contributing towards creating the required end tissue thickness which is an indication of a good seal.[0051]
• Preferably, the seal surfaces or[0052]tissue contacting surfaces151′,251′ (112,122) (See renumber FIGS.5′ and6A′-6G′) of thejaw members80′ and82′ (110 and120) are relatively flat to avoid current concentrations at sharp edges and to avoid arcing between high points. In addition and due to the reaction force of thetissue150 when engaged,jaw members80′ and82′ (110 and120) are preferably manufactured to resist bending. For example and as best seen in FIGS.2′ and6A′-6G′, thejaw members80′ and82′ (110 and120) are preferably tapered along width “W” which is advantageous for two reasons: 1) the taper will apply constant pressure for a constant tissue thickness at parallel; 2) the thicker proximal portion of thejaw members80′ and82′ (110 and120) will resist bending due to the reaction force of thetissue150.
• As best seen in FIG. 4′, in order to achieve a desired gap range (e.g., about 0.001 to about 0.005 inches and preferably about 0.002 inches to about 0.003 inches) and apply a desired force to seal the tissue, at least one[0053]jaw member80′ and/or82′ (110 and120) includes astop member139′ (150) which limits the movement of the two opposingjaw members80′ and82′ (110 and120) relative to one another. Preferably,stop member139′ (150) extends from the sealing surface ortissue contacting surface151′ (112 or122) a predetermined distance according to the specific material properties (e.g., compressive strength, thermal expansion, etc.) to yield a consistent and accurate gap distance during sealing.
• As explained above, in some cases it may be preferable to[0054]dimension stake119′ such that it acts like a stop member and/or an additional stop member and also controls/limits the movement of the two opposingjaw members80′ and82′ (110 and120) relative to one another. Preferably,stop member139′ (150) and/orstake119′ is made from an insulative material, e.g., parylene, nylon and/or ceramic and is dimensioned to limit opposing movement of thejaw members80′ and82′ (110 and120) to within the above gap range.
• FIG. 4A shows an exploded view of the various components of the[0055]forceps10 and the inter-operative relationships among the same. More particularly and in addition to the components described above with respect to FIGS.1-3 above,shaft12ais preferably hollow to define alongitudinal channel15adisposed therethrough which is dimensioned to receive atube60atherein.Tube60aincludes aproximal end64a, adistal end62aand at least one mechanical interface61adisposed therebetween.Shaft12aalso includes acover plate50 which is designed for snap-fit engagement within an aperture/cavity45adefined through the outer surface ofshaft12a.Cover plate50 includes a series of opposingflanges51aand51bwhich extend therefrom which are dimensioned to secure thetube60awithinshaft12aas described below. Asecond flange52 secures thecover plate50 to theshaft12a.
• During assembly, the[0056]proximal end64aoftube60ais slideable incorporated withinchannel15asuch that mechanical interface61ais poised for engagement withcover plate50.Cover plate50 is then snapped intocavity45asuch thatflanges51 a and51 bsecure tube60awithinshaft12a. It is envisioned that thecavity45aofshaft12amay include at least one detent (not shown) which engages mechanical interface61adisposed along the outer surface oftube60ato limit/prevent rotation of thetube60arelative to theshaft12a. This cooperative relationship is shown by way of example with respect todetents75aand75band interfaces (e.g., notches)61bofshaft12bin FIG. 8. In this instance,flanges51aand51b(much likeflanges42aand42bofcover plate40 in FIG. 8) hold thedetents75aand75bin FIG. 8) in secure engagement within the notch(es)61ato prevent rotational and/or longitudinal movement of thetube60awithin thechannel15a.
• Preferably, the proximal-most end of[0057]tube60aincludes a slit-like interface65awhich mechanically engages a corresponding tongue88aextending from the inner surface ofshaft12awithincavity45a. It is envisioned that tongue88aalso prevents rotational movement of thetube60awithin theshaft12a. Alternatively, slit65amay be formed to allow radial contraction and expansion of thetube60ato promote friction-fit engagement between thetube60aand theshaft12a. Other interfaces are also envisioned which will facilitate engagement of theshaft12aand thetube60a, e.g., snap-fit, spring-lock, locking tabs, screw-like interface, tongue and groove, etc.
• The[0058]distal end62aoftube60ais preferably dimensioned to engagejaw member120, i.e., thedistal end62aincludes a slit-like interface66awhich promotes simple, secure friction-fit engagement of thetube60awith thejaw member120. More particularly and as mentioned above,jaw member120 includes aproximally extending flange130 having asleeve128 extending proximally therefrom which is dimensioned such that, upon insertion of thesleeve128 withindistal end62a, slit-like interface66aexpands radially outwardly and securely locks thejaw member120 totube60a. Again, other methods of attachment are also envisioned which would serve the same purpose, e.g., snap-locks, locking tabs, spring-locks, screw-like interface, tongue and groove, etc.
• As can be appreciated by the present disclosure, the arrangement of[0059]shaft12bis slightly different fromshaft12aas shown best in FIGS. 4B, 7 and8. More particularly,shaft12bis also hollow to define achannel15btherethrough and is dimensioned to receive atube60btherein.Tube60bincludes a proximal end64band a distal end62bwhich attach in a generally similar fashion as their counterpart components with respect toshaft12a. For example, the proximal end64boftube60bis slideable incorporated withinchannel15bsuch that amechanical interface61 b disposed on the outer surface oftube60bis poised for engagement with a cover plate40 (FIGS. 4A and 8).
• Preferably and since the[0060]forceps10 is uniquely designed to incorporate all of the electrical interfaces and connections within and along a single shaft, e.g.,12b,shaft12bincludes a slightlylarger cavity45bdefined therein for housing and securing the various electrical connections associated with theforceps10 as described below. For example,cover plate40 is dimensioned slightly differently thancover plate50 mostly due to the spatial considerations which must be taken into account for incorporation of the various internally disposed electrical connections. However,cover plate40 does snap atopshaft12bsuch that a pair offlanges42aand42bsecure tube60bwithinshaft12bin a similar manner as described above. For example, FIG. 8 shows a pair ofdetents75aand75bdisposed within thecavity45bofshaft12bwhich engage a corresponding number ofmechanical interfaces61bdisposed along the outer surface oftube60bto limit/prevent rotation of thetube60brelative to theshaft12b. When assembled, eachflange42aand42bis pushed into a correspondinggroove73aand73b, respectively, which effectively maintain/hold thedetents75aand75bin secure engagement within thenotches61bto prevent rotational and/or longitudinal movement of thetube60bwithin thechannel15b.
• End[0061]64boftube60balso includes a slit-like interface65bwhich mechanically engages a corresponding tongue88bextending from the inner surface ofshaft12bwithincavity45b. It is envisioned that tongue88aalso prevents rotational movement of thetube60bwithin theshaft12b. Alternatively, slit65bmay be formed to allow radial contraction and expansion of thetube60bto promote friction-fit engagement between thetube60band theshaft12b.
• Unlike[0062]tube60a,tube60bis designed as an electrical conduit for transmitting electrosurgical energy tojaw member110 which is explained in more detail below with respect to FIGS. 7 and 8. The distal end62boftube60bis preferably dimensioned to engagejaw member110, i.e., the distal end62bincludes a slit-like interface66bwhich promotes simple, secure friction-fit engagement of thetube60bwith thejaw member110. This is best illustrated in FIG. 4B which shows proximally extendingflange130 ofjaw member110 having aterminal sleeve138 which extends therefrom.Terminal sleeve138 is dimensioned such that, upon insertion of theterminal sleeve138 within distal end62b, slit-like interface66bexpands radially outwardly and securely locks thejaw member110 totube60b.
• As can be appreciated,[0063]terminal end138 is at least partially made from an electrically conductive material such that an electrosurgical potential is effectively conducted from thetube60b, through theterminal sleeve138, acrossplate134 and to the electricallyconductive sealing plate112 upon activation. As mentioned above, the outerinsulative housing114 ofjaw member110 effectively eliminates stray electrical currents and incidental burning of tissue across the intended electrical path.
• As best shown in FIG. 4B,[0064]jaw member110 includes araceway135 extending proximally from theflange130 which includesterminal sleeve138 at the proximal-most end thereof. Theterminal sleeve138 connects to theconductive tube60bdisposed withinshaft12bas described above.Raceway135 serves two purposes: 1) to provide electrical continuity from theterminal sleeve138, through the electricallyconductive plate134 and to the electricallyconductive sealing surface112; and 2) to provide a channel for guidinglead210ato thedistal connector300 as described below.
• Insulated[0065]outer housing114 is dimensioned to securely engage the electricallyconductive sealing surface112. It is envisioned that this may be accomplished by stamping, by overmolding, by overmolding a stamped electrically conductive sealing plate and/or by overmolding a metal injection molded seal plate. All of these manufacturing techniques produce an electrode having an electricallyconductive surface112 which is substantially surrounded by an insulatedouter housing114.
• It is envisioned that the jaw member may also include a second insulator (not shown) disposed between the electrically[0066]conductive sealing surface112 and the outerinsulative housing114. The insulatedouter housing114 and the electrically conductive sealing surface112 (and the other insulator if utilized) are preferably dimensioned to limit and/or reduce many of the known undesirable effects related to tissue sealing, e.g., flashover, thermal spread and stray current dissipation.
• It is also envisioned that the electrically[0067]conductive sealing surface112 may include a pinch trim (not shown) which facilitates secure engagement of the electricallyconductive surface112 to the insulatedouter housing114 and also simplifies the overall manufacturing process. It is also contemplated that the electricallyconductive sealing surface112 may include an outer peripheral edge which has a radius and the insulatedouter housing114 meets the electricallyconductive sealing surface112 along an adjoining edge which is generally tangential to the radius and/or meets along the radius. Preferably, at the interface, the electricallyconductive surface112 is raised relative to the insulatedouter housing114. These and other envisioned embodiments are discussed in concurrently-filed, co-pending, commonly assigned Application Serial No. PCT/US01/11412 entitled “ELECTROSURGICAL INSTRUMENT WHICH REDUCES COLLATERAL DAMAGE TO ADJACENT TISSUE” by Johnson et al. and concurrently-filed, co-pending, commonly assigned Application Serial No. PCT/US01/11411 entitled “ELECTROSURGICAL INSTRUMENT WHICH IS DESIGNED TO REDUCE THE INCIDENCE OF FLASHOVER” by Johnson et al.
• As best illustrated in the exploded view of FIG. 4B, the inner periphery of[0068]tube60bis preferably dimensioned to house lead210atherethrough such that a different electrically potential can be effectively transmitted tojaw member120. More particularly and as mentioned above,cable210 houses twoleads210aand210bhaving different electrical potentials. Thefirst lead210ais disposed throughtube60band conducts the first electrical potential tojaw member120 as described in more detail below. Thesecond lead210bis electrically interfaced withtube60bat a proximal connector80 (FIG. 7) which includes a series ofelectrical crimps85,87 and89 for securinglead210btotube60b. As a result,tube60bcarries the second electrical potential therethrough for ultimate connection tojaw member110 as described above.
• Lead[0069]210apreferably includes aninsulative coating213 which surrounds an inner core or electrical conductor211 (e.g., wire) disposed therein to insulate theelectrical conductor211 from thetube60bduring activation. It is envisioned that thewire211 may be made from a solid or multi-strand electrically conductive material, e.g., copper/aluminum, which is surrounded by an insulative,non-conductive coating213, e.g., plastic.
• The[0070]wire211 includes aterminal end212 which is dimensioned to electrically interface withjaw member120. Preferably, theterminal end212 is “flat-formed” in a generally arcuate shape to encircle acorresponding boss314 which extends upwardly from thedistal connector300 towardsjaw member120 as described below. It is envisioned that thedistal connector300 performs at least two functions: 1) to insulatejaw member110 fromjaw member120; and 2) to provide a running electrical connection forlead210atojaw member120.
• More particularly, the[0071]distal connector300 is generally shaped to match the overall profile of the electricallyconductive face plates134 and144 ofjaw members110 and120, respectively, such that, upon assembly, outer facingsurfaces302 and304 of thedistal connector300 abut against the correspondingplates134 and144 ofjaw member110 and120, respectively. It is envisioned that the outer facingsurface302 of thedistal connector300 acts as a runway surface which facilitates pivotable motion ofjaw member120 aboutpivot pin151 relative tojaw member110. Preferably, thedistal connector300 is made form an insulative substrate such as plastic or some other non-conductive material.
• The distal connector includes a series of[0072]flanges322 and326 which extend towardsjaw member120 and a second series offlanges324 and328 which extend towardsjaw member110. It is envisioned that theseflanges322,324,326 and328 insulate the other operative components of theforceps10 and the patient from stray electrical currents emanating from the electricallyconductive plates134 and144 during activation.Flanges322 and328 may also be dimensioned to limit/restrict the expansion oftissue400 beyond the sealingsurfaces112 and122 during activation.Flanges326 and324 are preferably dimensioned to insulate the forceps during all angles of operation, i.e., pivoting of thejaw members110 and120.
• As mentioned above, the[0073]distal connector300 includes aboss314 which extends towardsjaw member120 which is dimensioned to secure theterminal end212 oflead210a. Preferably, the boss is designed to electrically insulate the terminal end of the lead from the pivot. Theboss314 preferably defines anaperture316 therethrough for receiving thepivot pin151 and to allow pivotable motion ofjaw member120 about thepivot151 and theboss314 relative tojaw member110.
• A continuous series of[0074]recesses312,318 and319 are formed around andproximate boss314 to seat the flat-formedterminal end212, thewire211 and the insulated portion of the lead210a, respectively. This also secures lead210ato the distal connector and limits movement of the same (210a). In some cases it may be preferable to include a dollop of silicone or other non-conductive material at the junction between the wire and theterminal end212 as an added and/or alternative insulating safeguard. It is also envisioned thatflange326 may include a notch (not shown) disposed therethrough which facilitates assembly of the lead210aatop thedistal connector300. As can be appreciated, this eliminates the step of forming the arcuately-shapedterminal end212 after insertion throughchannel318. As mentioned above, a dollop of silicone or the like may be added atop/within the notch for insulation purposes after theterminal end212 is seated within thedistal connector300.
• The proximal-most portion of[0075]distal connector300 includes afinger320 which is dimensioned to seat within achannel137 formed within theraceway135 such that thedistal connector300 moves in connection withjaw member110 during pivoting.Channel135 may be formed during a molding process, subsequently bored after theraceway135 is formed or by any other known method of formation. The uppermost edge ofboss314 is preferably dimensioned to seat within a corresponding recess (not shown) formed withinplate144. Likewise and although not shown, it is envisioned that the opposite end ofboss314 extends towardsplate134 and seats within arecess131 formed withinplate134. It is envisioned thatrecess131 promotes engagement of thedistal connector300 with thejaw member110.
• The[0076]distal connector300 also includes a spring washer orwave washer155 which is preferably dimensioned to encircle theboss314 atopterminal end212. Upon assembly, thewasher212 is sandwiched/wedged between theterminal end212 and theconductive plate144 ofjaw member120. It is envisioned that thewasher155 enhances the connection between the terminal end and theplate144. More particularly, thewasher155 is preferably shaped such that thewasher155 provides a self-cleaning, running electrical contact between theterminal end212 and thejaw member120. It is contemplated that thewasher155 “self-cleans” due to the frictional contact and relative movement of thewasher155 with respect to theterminal end212 during pivoting of thejaw members110 and120. The self-cleaning action can be attributed to thewasher155 rubbing, scoring and/or digging against theterminal end212 and/or theplate144 during pivoting of thejaw members110 and120.
• The outer housing of each of the[0077]jaw members110 and120 preferably includes an additional recess orcircular groove129 which receives a ring-like insulator153band153a, respectively.Insulators153aand153binsulate thepivot pin150 from thejaw members110 and120 when theforceps10 is assembled. Preferably thepivot pin150 is peened to secure thejaw members110 and120 during assembly and may includeouter rims151aand151bat least one of which is peened or formed after thejaw members110 and120 are assembled about thepivot pin150 as best shown in FIG. 4B.
• Upon activation, the first electrical potential is carried by[0078]lead210athroughtube60bto theterminal end212. Thewasher155 of thedistal connector300 then conducts the first potential to faceplate144 which carries the first potential to sealingplate122 disposed on the inner facing surface ofjaw member120. The second potential is carried bylead210bwhich electrically interfaces with thetube60b(by way ofcrimps85,87 and89) to conduct the second potential toterminal sleeve138 ofjaw member110. Theterminal sleeve138 electrically connects to sealingsurface112 acrossface plate134.
• FIG. 8 shows the connection of the[0079]cable210 within thecavity45bofshaft12b. As mentioned above a series of finger-like elements77aand77band crimps76aand76bsecure thecable210 withinshaft12b. Preferably,cable210 is secured at an angle alpha (a) relative to a longitudinal axis “A” disposed alongshaft12b. It is envisioned that angling thecable210 in an inward direction, i.e., towardsshaft12a, facilitates handling of theforceps10 and thecable210 during surgery, i.e., the angled disposition of thecable210 as it exits theforceps10 tends to reduce cable tangling and/or cable interference during handling.
• Preferably at least one of the[0080]jaw members110 and120 includes a skirt-like feature126 and136, respectively, which is dimensioned to prevent exposure of theterminal end212 orwire211 during all angles of operation, i.e., when thejaw members110 and120 are disposed in the first open position, the second closed position and/or during operative movement therebetween.
• It is envisioned that by making the[0081]forceps10 disposable, theforceps10 is less likely to become damaged since it is only intended for a single use and, therefore, does not require cleaning or sterilization. As a result, the functionality and consistency of the vital sealing components, e.g., theconductive surfaces112 and122, the stop member(s)150, and theinsulative housings124 and114 will assure a uniform and quality seal.
• From the foregoing and with reference to the various figure drawings, those skilled in the art will appreciate that certain modifications can also be made to the present disclosure without departing from the scope of the present disclosure. For example, it may be preferable to include a tang which facilitates manipulation of the[0082]forceps10 during surgery.
• Moreover, although the electrical connections are preferably incorporated with the[0083]bottom shaft12band the instrument is intended for right-handed use, it is contemplated the electrical connections may be incorporated with theother shaft12adepending upon a particular purpose and/or to facilitate manipulation by a left-handed user.
• It is also contemplated that a shrink tube may be employed over the[0084]proximal connector80 and/or the other various solder or crimpconnections85,87 and89 associated with theproximal connector80 interface withlead wire210b. This provides additional insulating protection during assembly. An insulative sheath may also be used to cover theend effector assembly100 or the outer surfaces (non-opposing surfaces) of thejaw members110 and120.
• It is also contemplated that the forceps[0085]10 (and/or the electrosurgical generator used in connection with the forceps10) may include a sensor or feedback mechanism (not shown) which automatically selects the appropriate amount of electrosurgical energy to effectively seal the particularly-sized tissue400 grasped between thejaw members110 and120. The sensor or feedback mechanism may also measure the impedance across the tissue during sealing and provide an indicator (visual and/or audible) that an effective seal has been created between thejaw members110 and120.
• Experimental results in animal studies suggest that the magnitude of pressure exerted on the tissue by the seal surfaces[0086]112 and122 is important in assuring a proper surgical outcome. Tissue pressures within a working range of about 3 kg/cm²to about 16 kg/cm²and, preferably, within a working range of 7 kg/cm²to 13 kg/cm²have been shown to be effective for sealing arteries and vascular bundles. Tissue pressures within the range of about 4 kg/cm²to about 6.5 kg/cm²have proven to be particularly effective in sealing arteries and tissue bundles.
• In one embodiment, the shaft portions are manufactured such that the spring constant of the[0087]shaft portions12aand12b, in conjunction with the placement of the ratchet interfaces32aand32b, will yield pressures within the above working range. In addition, the successive positions of the ratchet interfaces increase the pressure between opposing seal surfaces112 and122 incrementally within the above working range.
• It is envisioned that the outer surface of the[0088]jaw members110 and112 may include a nickel-based material, coating, stamping, metal injection molding which is designed to reduce adhesion between thejaw members110,112 (or components thereof) with the surrounding tissue during activation and sealing. Moreover, it is also contemplated that other components such as theshaft portions12a,12band the ring holes18a,18bmay also be coated with the same or a different “non-stick” material. Preferably, the non-stick materials are of a class of materials that provide a smooth surface to prevent mechanical tooth adhesions.
• It is also contemplated that the tissue sealing surfaces[0089]112 and122 of thejaw members110 and120 can be made from or coated with these non-stick materials. When utilized on the sealing surfaces112 and122, these materials provide an optimal surface energy for eliminating sticking due in part to surface texture and susceptibility to surface breakdown due electrical effects and corrosion in the presence of biologic tissues. It is envisioned that these materials exhibit superior non-stick qualities over stainless steel and should be utilized on theforceps10 in areas where the exposure to pressure and electrosurgical energy can create localized “hot spots” more susceptible to tissue adhesion. As can be appreciated, reducing the amount that the tissue “sticks” during sealing improves the overall efficacy of the instrument.
• The non-stick materials may be manufactured from one (or a combination of one or more) of the following “non-stick” materials: nickel-chrome, chromium nitride, MedCoat 2000 manufactured by The Electrolizing Corporation of OHIO, Inconel 600 and tin-nickel. For example, high nickel chrome alloys and Ni200, Ni201 (˜100% Ni) may be made into electrodes or sealing surfaces by metal injection molding, stamping, machining or any like process.[0090]
• The Inconel[0091]600 coating is a so-called “super alloy” which is manufactured by Special Metals, Inc. located in Conroe Texas. The alloy is primarily used in environments which require resistance to corrosion and heat. The high Nickel content of Inconel makes the material especially resistant to organic corrosion. As can be appreciated, these properties are desirable for bipolar electrosurgical instruments which are naturally exposed to high temperatures, high RF energy and organic matter. Moreover, the resistivity of Inconel is typically higher than the base electrode material which further enhances desiccation and seal quality.
• As mentioned above, the tissue sealing surfaces[0092]112 and122 may also be “coated” with one or more of the above materials to achieve the same result, i.e., a “non-stick surface”. For example, Nitride coatings (or one or more of the other above-identified materials) may be deposited as a coating on another base material (metal or nonmetal) using a vapor deposition manufacturing technique.
• One particular class of materials disclosed herein has demonstrated superior non-stick properties and, in some instances, superior seal quality. For example, nitride coatings which include, but not are not limited to: TiN, ZrN, TiAlN, and CrN are preferred materials used for non-stick purposes. CrN has been found to be particularly useful for non-stick purposes due to its overall surface properties and optimal performance. Other classes of materials have also been found to reducing overall sticking. For example, high nickel/chrome alloys with a Ni/Cr ratio of approximately 5:1 have been found to significantly reduce sticking in bipolar instrumentation. One particularly useful non-stick material in this class is Inconel 600. Bipolar instrumentation having sealing[0093]surfaces112 and122 made from or coated with Ni200, Ni201 (˜100% Ni) also showed improved non-stick performance over typical bipolar stainless steel electrodes.
• 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 exemplications of preferred embodiments. Those skilled in the art will envision other modifications within the scope and spirit of the claims appended hereto.[0094]

Claims (12)

What is claimed is:

1. A bipolar electrosurgical instrument for use in open surgery, comprising:

first and second shafts each having a jaw member extending from a distal end thereof and a handle disposed at a proximal end thereof for effecting movement of the jaw members relative to one another from a first position wherein the jaw members are disposed in opposable, spaced relation relative to one another to a second position wherein the jaw members cooperate to grasp tissue therebetween, each of the jaw members including an electrically conductive sealing surface;

a source of electrical energy having first and second electrical potentials, the first electrical potential being connected to one of the jaw members and a second electrical potential being connected to the other of the jaw members such that the jaw members are capable of selectively conducting energy through tissue held therebetween to effect a seal, wherein the first electrical potential is transmitted through the first shaft by a lead having a terminal end which electrically interfaces with a distal connector which connects one of the jaw members to the first electrical potential; and

at least one non-conductive stop member disposed on the electrically conductive sealing surface of at least one of the jaw members which controls the distance between the electrically conductive sealing surfaces when tissue is held therebetween.

2. A bipolar electrosurgical instrument for use in open surgery according toclaim 1 wherein the at least one non-conductive stop creates a gap between the electrically conductive sealing surfaces within the range of about 0.001 inches to about 0.006 inches.

3. A bipolar electrosurgical instrument for use in open surgery according toclaim 1 wherein the non-conductive stop creates a gap between the electrically conductive sealing surfaces within the range of about 0.002 inches to about 0.003 inches.

4. A bipolar electrosurgical instrument for use in open surgery, comprising:

first and second shafts each having a jaw member extending from a distal end thereof and a handle disposed at a proximal end thereof for effecting movement of the jaw members relative to one another from a first position wherein the jaw members are disposed in opposable, spaced relation relative to one another to a second position wherein the jaw members cooperate to grasp tissue therebetween, each of the jaw members including an electrically conductive sealing surface;

a source of electrical energy having first and second electrical potentials, the first electrical potential being connected to one of the jaw members and a second electrical potential being connected to the other of the jaw members such that the jaw members are capable of selectively conducting energy through tissue held therebetween to effect a seal, wherein the first electrical potential is transmitted through the first shaft by a lead having a terminal end which electrically interfaces with a distal connector which connects one of the jaw members to the first electrical potential;

at least one non-conductive stop member disposed on the electrically conductive sealing surface of at least one of the jaw members which controls the distance between the electrically conductive sealing surfaces when tissue is held therebetween; and

a ratchet disposed on the first shaft and at least one complimentary interlocking mechanical interface disposed on the second shaft, the ratchet and the complimentary interlocking mechanical interface providing at least one interlocking position to maintain a closure pressure in the range of about 3 kg/cm²to about 16 kg/cm²between the electrically conductive sealing surfaces.

5. A bipolar electrosurgical instrument according toclaim 4 wherein the ratchet and the complimentary interlocking mechanical interface provide at least one interlocking position to maintain a closure pressure in the range of about 7 kg/cm²to about 13 kg/cm²between the electrically conductive sealing surfaces.

6. A bipolar electrosurgical instrument according toclaim 4 further comprising a non-stick material disposed on the electrically conductive sealing surfaces.

7. A bipolar electrosurgical instrument according toclaim 4 wherein the nonconductive stop member is disposed adjacent the electrically conductive sealing surfaces.

8. A bipolar electrosurgical instrument according toclaim 6 wherein the nonstick material is a coating which is deposited on the electrically conductive sealing surfaces.

9. A bipolar electrosurgical instrument according toclaim 8 wherein the nonstick coating is selected from a group of materials consisting of: nitrides and nickel/chrome alloys.

10. A bipolar electrosurgical instrument according toclaim 8 wherein the nonstick coating includes one of TiN, ZrN, TiAlN, CrN, nickel/chrome alloys with a Ni/Cr ratio of approximately 5:1, Inconel 600, Ni200 and Ni201.

11. A bipolar electrosurgical instrument according toclaim 6 wherein the electrically conductive sealing surfaces are manufactured from a non-stick material.

12. A bipolar electrosurgical instrument for use in open surgery, comprising:

first and second shafts each having a jaw member extending from a distal end thereof and a handle disposed at a proximal end thereof for effecting movement of the jaw members relative to one another from a first position wherein the jaw members are disposed in spaced relation relative to one another to a second position wherein the jaw members cooperate to grasp tissue therebetween, each of the jaw members including an electrically conductive sealing surface;

a source of electrical energy having a first electrical potential connected to one of the jaw members and a second electrical potential connected to the other of the jaw members such that the jaw members are capable of selectively conducting energy through tissue held therebetween to effect a seal;

the first and second electrical potentials being transmitted to the jaw members through the first shaft wherein the first electrical potential is transmitted by a lead having a terminal end which electrically interfaces with a spring washer, the spring washer acting as an electrical intermediary between the terminal end and the jaw member;

at least one non-conductive stop member disposed on the electrically conductive sealing surface of at least one of the jaw members which controls the distance between the jaw members when tissue is held therebetween, wherein the at least one non-conductive stop creates a gap between the electrically conductive surfaces within the range of about 0.001 inches to about 0.006 inches; and

a ratchet disposed on the first shaft and at least one complimentary interlocking mechanical interface disposed on the second shaft, the ratchet and the complimentary interlocking mechanical interface providing at least one interlocking position to maintain a closure pressure in the range of about 3 kg/cm²to about 16 kg/cm²between the electrically conductive sealing surfaces.

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