Abstract: The disclosure provides a method of manufacturing a flexible circuit electrode assembly and an apparatus manufactured by said method. According to the method, an electrically conductive sheet is laminated to an electrically insulative sheet. An electrode is formed on the electrically conductive sheet. An electrically insulative layer is formed on a tissue contacting surface of the electrode. The individual electrodes are separated from the laminated electrically insulative sheet and the electrically conductive sheet. In another method, a flexible circuit is vacuum formed to create a desired profile. The vacuum formed flexible circuit is trimmed. The trimmed vacuum formed flexible circuit is attached to a jaw member of a clamp jaw assembly.

Abstract: A surgical instrument comprising a waveguide, an end effector, and an electrical switch is disclosed. The waveguide comprises a proximal end and a distal end, wherein the proximal end is configured to couple to an ultrasonic transducer and one output of a radio frequency (RF) generator. The end effector may comprise an ultrasonic blade and a clamp arm. The ultrasonic blade is mechanically coupled to the distal end of the waveguide and electrically coupled to the waveguide. The clamp arm comprises a movable jaw member electrically coupled to another output of the RF generator. The electrical switch is operable to cause the surgical instrument to deliver electrical current from the RF generator to the movable jaw member for a first period, and to cause the surgical instrument to deliver ultrasonic energy to the ultrasonic blade for a second period.

Abstract: A surgical system includes a first detector that includes a first array of pixels configured to detect light reflected by a surgical instrument and generate a first signal comprising a first dataset representative of a visible image of the surgical instrument. The surgical system also includes a second detector, comprising a second array of pixels configured to detect infrared radiation produced by the surgical instrument during a procedure using the surgical instrument and generate a second signal comprising a second dataset representative of an infrared image of the surgical instrument. The surgical system further includes a processor configured to receive the first and second signals, identify from the first dataset data representative of the surgical instrument, and identify from the second dataset data representative of one or more regions of the surgical instrument above a predetermined threshold temperature.

Abstract: Surgical devices and methods are described herein that provide improved motor control and feedback, thereby combining advantages of manually-operated and powered surgical devices. In one embodiment, a surgical device includes a proximal handle portion that includes a motor, a distal end effector coupled to the handle portion, and a cutting element configured to cut tissue engaged by the end effector, wherein the motor is configured to supply power that moves the cutting element. The device also includes a motor control mechanism configured to cause the amount of the power to dynamically change in response to a manual user input when the cutting element is moving.

Abstract: A surgical instrument comprises a shaft assembly comprising a shaft and an end effector coupled to a distal end of the shaft; a handle assembly coupled to a proximal end of the shaft; a battery assembly coupled to the handle assembly; a radio frequency (RF) energy output powered by the battery assembly and configured to apply RF energy to a tissue; an ultrasonic energy output powered by the battery assembly and configured to apply ultrasonic energy to the tissue; and a controller configured to, based at least in part on a measured tissue characteristic, start application of RF energy by the RF energy output or application of ultrasonic energy by the ultrasonic energy output at a first time.

Abstract: A surgical system includes a first detector that includes a first array of pixels configured to detect light reflected by a surgical instrument and generate a first signal comprising a first dataset representative of a visible image of the surgical instrument. The surgical system also includes a second detector, comprising a second array of pixels configured to detect infrared radiation produced by the surgical instrument during a procedure using the surgical instrument and generate a second signal comprising a second dataset representative of an infrared image of the surgical instrument. The surgical system further includes a processor configured to receive the first and second signals, identify from the first dataset data representative of the surgical instrument, and identify from the second dataset data representative of one or more regions of the surgical instrument above a predetermined threshold temperature.

Abstract: Surgical devices and methods are described herein that provide improved motor control and feedback, thereby combining advantages of manually-operated and powered surgical devices. In one embodiment, a surgical device includes a proximal handle portion that includes a motor, a distal end effector coupled to the handle portion, and a cutting element configured to cut tissue engaged by the end effector, wherein the motor is configured to supply power that moves the cutting element. The device also includes a motor control mechanism configured to cause the amount of the power to dynamically change in response to a manual user input when the cutting element is moving.

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: Various embodiments of surgical robot control systems are disclosed. In one example embodiment, the surgical robot control system comprises a housing. A controller is located within the housing and is coupled to a socket. The socket receives a handheld surgical user interface therein to control a surgical instrument. The surgical instrument is connected to the surgical robot and comprises an end effector and a mechanical interface to manipulate the end effector. The mechanical interface is coupled to the controller. At least one sensor is coupled to the controller and the socket to convert movement of the handheld surgical user interface into electrical signals corresponding to the movement of the surgical instrument. At least one feedback device is coupled to the controller to provide feedback to a user. The feedback is associated with a predetermined function of the surgical instrument.

Abstract: A surgical system includes a detector that includes an array of pixels configured to detect light reflected by a surgical device and generate a first signal. The first signal includes a first dataset representative of a visible image of the surgical device. The surgical system also includes a processor configured to receive the first signal and a second signal representative of one or more operating parameters of the surgical device. The processor is also configured to generate a modified image of the surgical device that includes information related to one or more operating parameters.

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 instrument comprises a shaft assembly comprising a shaft and an end effector coupled to a distal end of the shaft; a handle assembly coupled to a proximal end of the shaft; a battery assembly coupled to the handle assembly; a radio frequency (RF) energy output powered by the battery assembly and configured to apply RF energy to a tissue; an ultrasonic energy output powered by the battery assembly and configured to apply ultrasonic energy to the tissue; and a controller configured to, based at least in part on a measured tissue characteristic, start application of RF energy by the RF energy output or application of ultrasonic energy by the ultrasonic energy output at a first time.

Abstract: A surgical instrument comprises a shaft assembly comprising a shaft and an end effector coupled to a distal end of the shaft; a handle assembly coupled to a proximal end of the shaft; a battery assembly coupled to the handle assembly; a radio frequency (RF) energy output powered by the battery assembly and configured to apply RF energy to a tissue; an ultrasonic energy output powered by the battery assembly and configured to apply ultrasonic energy to the tissue; and a controller configured to, based at least in part on a measured tissue characteristic, start application of RF energy by the RF energy output or application of ultrasonic energy by the ultrasonic energy output at a first time.

Abstract: Various forms are directed to systems and methods for dissection and coagulation of tissue. A method for detecting a short circuit in a surgical system configured to apply radio frequency energy and ultrasonic energy to a target surgical site that includes delivering radio frequency (RF) energy to an electrode of a surgical instrument, transitioning from delivering the RF energy to delivering ultrasonic energy to an ultrasonic blade of the surgical instrument, delivering an exploratory ultrasonic pulse to the ultrasonic blade, measuring an ultrasonic property of tissue engaged by the surgical instrument, wherein the ultrasonic property is associated with the exploratory ultrasonic pulse, determining whether the measured ultrasonic property is consistent with a behavior of low impedance tissue, and delivering ultrasonic energy to the ultrasonic blade to cut the tissue upon determining that the measured ultrasonic property is consistent with ultrasonic energy being applied to low impedance tissue.

Abstract: Disclosed is a surgical instrument with an end-effector adapted and configured to deliver a plurality of energy modalities to tissue at a distal end thereof. The energy modalities may be applied simultaneously, independently, or sequentially. A generator is electrically coupled to the surgical instrument and is configured to supply a plurality of energy modalities to the end-effector. In one aspect, the generator is configured to supply electrosurgical energy (e.g., monopolar or bipolar radio frequency (RF) energy) and ultrasonic energy to the end-effector to allow the end-effector to interact with the tissue. The energy modalities may be supplied to the end-effector by a single generator or multiple generators.

Abstract: An end-effector configured to grasp tissue is disclosed herein. The end-effector includes an ultrasonic blade configured to transfer ultrasonic energy to the tissue and a clamp arm. The clamp arm includes a clamp arm pad including an electrically conductive material and an electrically non-conductive material. The clamp arm pad is configured as an electrode of a radiofrequency energy circuit, wherein the electrode is configured to transfer radiofrequency energy through the tissue to a return electrode of the radiofrequency energy circuit, and wherein the electrically non-conductive material is configured to reduce the possibility of an electrical short between the electrically conductive material and the ultrasonic blade as the clamp arm pad degrades throughout the usable life of the end effector.

Abstract: An end-effector is disclosed. The end-effector includes a clamp arm and an ultrasonic blade configured to acoustically couple to an ultrasonic transducer and electrically couple to a pole of an electrical generator. The clamp arm includes a clamp jaw and an electrode configured to electrically couple to an opposite pole of the electrical generator. In one configuration, the electrode is segmented. In another configuration, the ultrasonic blade includes electrically insulative material deposited on selected areas to prevent electrical shorting in the event of the ultrasonic blade contacts the electrode. In another configuration, the clamp arm, the ultrasonic blade, or both include selectively coated components.

Abstract: An end-effector including a clamp arm and an ultrasonic blade configured to acoustically couple to an ultrasonic transducer and to electrically couple to a pole of an electrical generator. The clamp arm includes a clamp jaw and an electrically conductive polymer clamp arm pad. The clamp arm may include electrically non-conductive layers and electrically conductive layers arranged in a sandwich like configuration to electrically couple to an opposite pole of the electrical generator. The clamp arm may include a composite clamp arm pad attached to the clamp jaw, the composite clamp arm pad includes electrically non-conductive layers and electrically conductive layers to couple to an opposite pole of the electrical generator. The clamp arm may include a carrier attached to the clamp jaw and a clamp arm pad including an electrically non-conductive pad and an electrically conductive pad to couple to an opposite pole of the electrical generator.

Abstract: An end-effector and a surgical instrument including the end-effector are disclosed. The end-effector includes a clamp arm and an ultrasonic blade configured to acoustically couple to an ultrasonic transducer and to electrically couple to a pole of an electrical generator. The clamp arm includes a clamp jaw, a cantilever electrode configured to electrically couple to an opposite pole of the electrical generator and an electrically non-conductive clamp arm pad including a plurality of teeth. The surgical instrument includes a control circuit to detect a distal conductive element contact with the ultrasonic blade and adjust power applied to the ultrasonic blade based on detection of the contact.