Abstract: A surgical tool that includes a drive housing, an elongate shaft that extends from the drive housing, and an end effector arranged at a distal end of the elongate shaft and including a jaw secured to a jaw holder, the jaw providing a conductive plate and the jaw holder defining a passage. A wrist couples the end effector to the elongate shaft and includes a distal clevis having an axle that rotatably mounts the jaw holder to the distal clevis. An electrical conductor extends from the drive housing, through the wrist and the passage, and terminates at the conductive plate to supply electrical energy to the jaw.

Abstract: A tool for installing and/or removing a protective cover of an instrument includes a body portion having an open end and a closed end. The open end defines an interior passage that extends into the body portion along a longitudinal axis of the body portion toward the closed end of the body portion. The interior passage is configured to receive at least a portion of the protective cover in the interior passage. One or more members are connected to the body portion, and each of the one or more members includes a free end movable relative to the body portion. Systems and methods relate to tools for installing and/or removing protective covers of instruments.

Abstract: An electrosurgical return electrode includes a conductive layer and a plug connected thereto. The conductive layer is configured to conduct electrical current and has one or more apertures extending therethrough. The plug includes a base having one or more bosses configured to extend through the one or more apertures in the conductive layer. The plug also includes a cap disposed adjacent to the conductive layer and opposite to the base. The cap and the base are laser or ultrasonically welded together or the conductive layer, the base, and the cap are joined together via an adhesive.

Abstract: A surgical tool that includes a drive housing, an elongate shaft that extends from the drive housing, and an end effector arranged at a distal end of the elongate shaft and including a jaw secured to a jaw holder, the jaw providing a contact plate and the jaw holder defining a cable passage. A wrist couples the end effector to the elongate shaft and includes a distal clevis having an axle that rotatably mounts the jaw holder to the distal clevis. An electrical conductor extends from the drive housing, through the wrist and the cable passage, and terminates at the contact plate to supply electrical energy to the jaw.

Abstract: Methods of manufacturing a medical device are provided, which include injection molding a substantially cylindrical monolithic outer shell having an inner lumen and a plurality of ribs spaced longitudinally and extending partially circumferentially around the substantially cylindrical monolithic outer shell with elongate slots separating each rib. At least one flexible divider can be injection molded and advanced into the inner lumen to separate the inner lumen into first and second elongate channels and can be freely slidable relative to the substantially cylindrical monolithic outer shell. Proximal and distal ends of the substantially cylindrical monolithic outer shell can be respectively mated to a distal end of the elongate shaft and a proximal end of an end effector. First and second articulation bands can be advanced through the elongate shaft and channels and mated to opposed sides of the end effector.

Abstract: A sleeve extractor includes a cylindrical body having a distal end and a proximal end, one or more longitudinally-extending fingers defined in the body, and a tab provided on an end of each finger and receivable within a notch defined in a shaft adapter or a shaft of a surgical tool, the notch being located proximal to a proximal end of a sleeve. The sleeve is removed by locating the tab of each finger in a corresponding notch and retracting the body and the sleeve distally relative to the shaft adapter or the shaft.

Abstract: A surgical tool that includes a drive housing, an elongate shaft that extends from the drive housing, and an end effector arranged at a distal end of the elongate shaft and including a jaw secured to a jaw holder, the jaw providing a contact plate and the jaw holder defining a cable passage. A wrist couples the end effector to the elongate shaft and includes a distal clevis having an axle that rotatably mounts the jaw holder to the distal clevis. An electrical conductor extends from the drive housing, through the wrist and the cable passage, and terminates at the contact plate to supply electrical energy to the jaw.

Abstract: A surgical tool that includes a drive housing, an elongate shaft that extends from the drive housing, and an end effector arranged at a distal end of the elongate shaft and having a jaw and a jaw holder that secures the jaw. A wrist couples the end effector to the elongate shaft and includes a distal clevis having an axle that rotatably mounts the jaw holder to the distal clevis. An electrical conductor extends from the drive housing and supplies electrical energy to the jaw via a supply conductor. At least one of the jaw holder and the axle is made of a non-conductive material that insulates the distal clevis from the electrical energy provided to the jaw.

Abstract: Methods and devices for allowing articulation of an end effector on a surgical instrument are provided. In one embodiment, a surgical device can include a flexible neck portion having an end effector coupled to a distal end thereof. The flexible neck portion is configured to bend to as to allow the end effector to articulate. The flexible neck portion can include a monolithic flexible outer shell defining an inner lumen extending therethrough. At least one flexible divider can be disposed within the inner lumen such that it separates the outer shell into elongate pathways configured to receive articulation members extending through the shaft assembly and the flexible neck and coupled to the end effector to cause articulating movement thereof.

Abstract: Methods and devices for allowing articulation of an end effector on a surgical instrument are provided. In one embodiment, a surgical device can include a flexible neck portion having an end effector coupled to a distal end thereof. The flexible neck portion is configured to bend to as to allow the end effector to articulate. The flexible neck portion can include a monolithic flexible outer shell defining an inner lumen extending therethrough. At least one flexible divider can be disposed within the inner lumen such that it separates the outer shell into elongate pathways configured to receive articulation members extending through the shaft assembly and the flexible neck and coupled to the end effector to cause articulating movement thereof.

Abstract: Electrosurgical instruments with passive articulation and thermal insulation are described herein. Such instruments can provide the advantages associated with passive articulation while protecting tissue and other structures from unintentional thermal damage when an end effector is pressed thereagainst to effect articulation while at an elevated temperature due to use. In one embodiment, such an instrument can include a distal end effector with jaws to clamp tissue, a proximal actuating portion, an energy delivery surface that contacts grasped tissue, and a passive articulating portion disposed between the end effector and the actuating portion. The articulating portion can be configured to selectively permit movement of the end effector relative to the actuating portion in response to external forces acting on the end effector. Further, an outward-facing surface of at least one of the first and second jaws can be covered in a thermally insulating material.

Abstract: Surgical instruments having articulating and rotating end effectors utilizing a flexible coaxial drive are described herein. In one embodiment, a surgical instrument is provided that includes a shaft and an end effector coupled to a distal end of the shaft by an articulation joint such that the end effector can articulate relative to a longitudinal axis of the shaft and can rotate about a longitudinal axis of the end effector. The instrument can further include an actuating cable coaxially disposed within a lumen of the shaft and extending through the articulation joint to the end effector. The actuating cable can be configured to bend and rotate through the articulation joint. Further, rotation of the actuating cable can be configured to control a first function of the end effector and translation of the actuating cable can be configured to control a second function of the end effector.

Abstract: Surgical instruments having articulating portions or joints are described herein. In one embodiment, a surgical instrument can include a distal end effector, a proximal actuating portion, and an articulating portion disposed between the end effector and the actuating portion. The articulating portion can include an inner component formed of a first material and an outer component formed of a second material, wherein a modulus of elasticity of the first material is higher than a modulus of elasticity of the second material. Such an instrument can be less complex and less expensive than known articulation mechanisms while providing similar capabilities.

Abstract: Methods and devices for allowing articulation of an end effector on a surgical instrument are provided. In one embodiment, a surgical device can include a flexible neck portion having an end effector coupled to a distal end thereof. The flexible neck portion is configured to bend to as to allow the end effector to articulate. The flexible neck portion can include a monolithic flexible outer shell defining an inner lumen extending therethrough. At least one flexible divider can be disposed within the inner lumen such that it separates the outer shell into elongate pathways configured to receive articulation members extending through the shaft assembly and the flexible neck and coupled to the end effector to cause articulating movement thereof.

Abstract: A surgical tool that includes a drive housing, an elongate shaft that extends from the drive housing, and an end effector arranged at a distal end of the elongate shaft and having a jaw and a jaw holder that secures the jaw. A wrist couples the end effector to the elongate shaft and includes a distal clevis having an axle that rotatably mounts the jaw holder to the distal clevis. An electrical conductor extends from the drive housing and supplies electrical energy to the jaw via a supply conductor. At least one of the jaw holder and the axle is made of a non-conductive material that insulates the distal clevis from the electrical energy provided to the jaw.

Abstract: Methods and devices for allowing articulation of an end effector on a surgical instrument are provided. In one embodiment, a surgical device can include a flexible neck portion having an end effector coupled to a distal end thereof. The flexible neck portion is configured to bend to as to allow the end effector to articulate. The flexible neck portion can include a monolithic flexible outer shell defining an inner lumen extending therethrough. At least one flexible divider can be disposed within the inner lumen such that it separates the outer shell into elongate pathways configured to receive articulation members extending through the shaft assembly and the flexible neck and coupled to the end effector to cause articulating movement thereof.

Abstract: Surgical instruments having articulating and rotating end effectors utilizing a flexible coaxial drive are described herein. In one embodiment, a surgical instrument is provided that includes a shaft and an end effector coupled to a distal end of the shaft by an articulation joint such that the end effector can articulate relative to a longitudinal axis of the shaft and can rotate about a longitudinal axis of the end effector. The instrument can further include an actuating cable coaxially disposed within a lumen of the shaft and extending through the articulation joint to the end effector. The actuating cable can be configured to bend and rotate through the articulation joint. Further, rotation of the actuating cable can be configured to control a first function of the end effector and translation of the actuating cable can be configured to control a second function of the end effector.

Abstract: Electrosurgical instruments with passive articulation and thermal insulation are described herein. Such instruments can provide the advantages associated with passive articulation while protecting tissue and other structures from unintentional thermal damage when an end effector is pressed thereagainst to effect articulation while at an elevated temperature due to use. In one embodiment, such an instrument can include a distal end effector with jaws to clamp tissue, a proximal actuating portion, an energy delivery surface that contacts grasped tissue, and a passive articulating portion disposed between the end effector and the actuating portion. The articulating portion can be configured to selectively permit movement of the end effector relative to the actuating portion in response to external forces acting on the end effector. Further, an outward-facing surface of at least one of the first and second jaws can be covered in a thermally insulating material.

Abstract: Surgical instruments having articulating portions or joints are described herein. In one embodiment, a surgical instrument can include a distal end effector, a proximal actuating portion, and an articulating portion disposed between the end effector and the actuating portion. The articulating portion can include an inner component formed of a first material and an outer component formed of a second material, wherein a modulus of elasticity of the first material is higher than a modulus of elasticity of the second material. Such an instrument can be less complex and less expensive than known articulation mechanisms while providing similar capabilities.

Abstract: Methods and devices for allowing articulation of an end effector on a surgical instrument are provided. In one embodiment, a surgical device can include a flexible neck portion having an end effector coupled to a distal end thereof. The flexible neck portion is configured to bend to as to allow the end effector to articulate. The flexible neck portion can include a monolithic flexible outer shell defining an inner lumen extending therethrough. At least one flexible divider can be disposed within the inner lumen such that it separates the outer shell into elongate pathways configured to receive articulation members extending through the shaft assembly and the flexible neck and coupled to the end effector to cause articulating movement thereof.