DE102022125714A1 - Electrosurgical tool and method of manufacturing - Google Patents

Abstract

An electrosurgical tool (40) for an electrosurgical instrument (10) comprises a first jaw part (52), a second jaw part (54) and a flexible conductor component (60) with an electrically insulating substrate (64) and a plurality of first electrode surfaces (82) on a first surface region (82) of the flexible conductor component (60), wherein at least a first partial region (72) of the flexible conductor component (60) is mechanically connected to the first jaw part (52), and wherein the first surface region (82) on the first partial region (72) of the flexible conductor component (60) with the plurality of first electrode surfaces (86) forms at least part of a first gripping surface (56) on the first jaw part (52).

Description

The present invention is directed to an electrosurgical tool, an electrosurgical instrument with an electrosurgical tool, and a method of manufacturing an electrosurgical tool.

Electrosurgery involves the electrothermal heating of tissue to denature, coagulate, cauterize, vaporize, ablate, or transect it. Electrosurgical instruments and the electrosurgical tools at the distal ends of electrosurgical instruments are becoming increasingly miniaturized and undergoing further improvements. This includes the use of a higher number of electrode surfaces to control current flows more precisely.

In EP1 632 192A1 describes an instrument for closing vessels, which has two gripping jaws that can be moved relative to one another. Each gripping jaw comprises a pair of electrically conductive, spaced-apart vessel-closing surfaces that extend along the gripping jaw. Each pair of vessel-closing surfaces is connected to a source of electrosurgical energy. The gripping jaws can be mirror-imaged or non-mirror-imaged.

In US 2007-0156139 A1 (also published as US7,776,036 B2 ) describes a bipolar electrosurgical forceps having a pair of opposing jaws with tissue-grasping surfaces. A plurality of ring-like electrodes are provided on one of the tissue-grasping surfaces, and a plurality of post electrodes are arranged on the other tissue-grasping surface.

In US 2010-274244 A1 (also published as US 8,277,446 A1 ) an instrument for electrosurgically closing and cutting tissue is described. The instrument comprises a pair of jaws with opposing tissue-grasping surfaces on which electrodes arranged in a row and insulated from one another are arranged. The instrument further comprises a controller for supplying electrical energy to a particular electrode while other electrodes are in an inactive state. A sensor array communicating with the controller senses a property of the tissue indicative of a completed electrosurgical treatment. The sensor array may comprise an impedance sensor.

In US 2016/0287316 A1 (also published as US10,813,684 B2 ) describes the control of electrosurgical tissue closure and severance. Electrodes on gripping surfaces on jaws are divided into zones. Each zone can include a monitoring device for measuring the impedance in the zone.

In US 2016/0302854 A1 (also published as US9,717,550 B2 ) describes an electrosurgical forceps with jaws whose gripping surfaces or closing plates each consist of a plurality of segments which are electrically insulated from one another by insulating components. The segments may be preselected or dynamically selected as components of one or more electrical circuits which provide electrosurgical energy to tissue arranged between the jaws. For example, a first bipolar circuit may comprise outer segments, a second bipolar circuit may comprise middle segments and a third bipolar circuit may comprise inner segments, wherein the first, second and third circuits can be activated independently of one another to provide electrosurgical energy to the tissue. A generator with a controller, a sensor module and a multiplexer measures the impedance of tissue positioned between two selected segments and, on the basis of the measured values, the generator forms one or more bipolar circuits between selected segments (paragraph [0049]). Each closing plate is connected to the associated jaw housing by a plate support, which may be formed as part of the closing plate or as part of the jaw housing or as a stand-alone component. The plate support may include a circuit, a printed circuit board or connections that connect the segments to the electrical power source.

In EP 2 149 342 A1 describes a multiphase electrosurgical system with an array of electrodes. A multiphase high frequency generator is designed to generate a plurality of independent high frequency signals whose phase, amplitude and/or frequency can be independently varied. The high voltage signals can have substantially sinusoidal or non-sinusoidal waveforms, and each independent signal can be applied to a corresponding electrode of the surgical instrument. A sensor module can detect biometric parameters such as the tissue impedance "corresponding to the application of the electrosurgical waveforms to the tissue". A controller can adjust the phase, amplitude and/or frequency depending on the biometric parameter, mentioning the formation of vapor bubbles (ibid.). In the figures, parallel needle-shaped electrodes can be seen arranged at the corners of regular polygons or forming the corners of rows of triangles.

An object of the present invention is to provide an improved electrosurgical tool and an improved method of manufacturing an electrosurgical tool.

This problem is solved by the subject matter of the independent claims.

Further embodiments are defined in the dependent claims.

An electrosurgical tool for an electrosurgical instrument comprises a first jaw part, a second jaw part and a flexible conductor component with an electrically insulating substrate and a plurality of first electrode surfaces on a first surface region of the flexible conductor component, wherein at least a first partial region of the flexible conductor component is mechanically connected to the first jaw part, wherein the first surface region of the flexible conductor component with the plurality of first electrode surfaces forms at least part of a first gripping surface on the first jaw part.

The flexible conductor component is in particular flat, i.e. thin and essentially two-dimensional. This means that its surface is essentially formed by two surface areas facing away from each other and essentially parallel, wherein the distance between the surface areas is much smaller than the linear dimensions of the surface areas.

A surface area of the first jaw part facing the second jaw part forms the first gripping surface of the first jaw part. A surface area of the second jaw part facing the first jaw part forms the second gripping surface of the second jaw part. Both gripping surfaces are in particular designed to correspond, so that both gripping surfaces can lie flat or essentially flat against one another. One or both gripping surfaces can be structured to prevent gripped tissue from slipping away, thus enabling more secure gripping, or to improve the electrosurgical closure of vessels or other tissue. One or both gripping surfaces have a structure or profiling, for example similar to a waffle or a waffle iron. The structure or profiling has, for example, the shape of a rectangular, oblique-angled or hexagonal grid. The structure or profiling can repeat periodically or quasi-periodically or non-periodically in one or two directions. Both gripping surfaces can then touch each other in many small, regularly or irregularly arranged, but in particular with a substantially constant density, point-like or more extensive surfaces or in a grid of non-intersecting or intersecting lines. In these cases too, there is an essentially flat contact of one gripping surface with the other gripping surface.

Alternatively, both gripping surfaces are shaped such that, at a predetermined distance, both gripping surfaces are essentially parallel to each other. This does not exclude a profile or structuring of one or both gripping surfaces as described above.

In the case of a gripping surface with a profile or structure, the flexible conductor component and a surface area of an underlying mechanical structural component of the jaw part are in particular conformal, i.e. they have corresponding geometric shapes, so that the flexible conductor component rests over its entire surface or substantially over its entire surface on the surface area of the underlying mechanical structural component of the jaw part.

A profile or structuring of a flexible conductor component does not necessarily require a non-zero Gaussian curvature. For example, the flexible conductor component can be folded or pleated - similar to origami.

Alternatively, the flexible conductor component can have a Gaussian curvature that is different from zero locally or over a large area. A flexible conductor component can originally have been manufactured with this Gaussian curvature or even with the specific profile or the specific structuring. Alternatively, the flexible conductor component that was originally manufactured flat or with a vanishing Gaussian curvature can be given the profile or structuring by (optionally thermally supported) plastic deformation, for example embossing.

The electrode surfaces of the plurality of electrode surfaces are exposed on the first gripping surface on the first jaw part. This means that each individual electrode surface of the plurality of electrode surfaces can directly mechanically touch tissue held or squeezed between the gripping surfaces of the jaw parts and form a conductive contact with them.

The electrode surfaces of the plurality of electrode surfaces are in particular electrically insulated from one another and can be connected or are connected independently of one another to an electrical power source and/or an electrical measuring device for measuring an impedance and/or another electrical property or characteristic. Alternatively, within one or more groups, a plurality of first electrode surfaces can be electrically connected in parallel with one another.

The measurement of the impedances and/or other electrical properties or parameters between different pairs of electrode surfaces can enable a spatially differentiated recording of the electrical properties of tissue between the jaw parts. In the ideal case of a very large number of very small first electrode surfaces, the measurement of the impedances and/or other electrical properties or parameters between a very large number of different pairs of electrode surfaces can enable an approximate tomographic recording of the electrical properties of tissue between the jaw parts. Likewise, the plurality of electrode surfaces on each gripping surface can enable a spatially differentiated current supply and thus also a spatially differentiated electrosurgical effect, in particular heating and cauterization of tissue. For example, depending on the spatially differentiated recorded state of tissue, the voltage, current and/or applied power can be limited locally in a differentiated manner in order to avoid overheating of the tissue. The properties of the tissue can be recorded first and then the tissue can be energized, or alternatively, the recording and energization can take place alternately or intermittently or partially or completely simultaneously.

The flexible conductor component can be permanently mechanically connected to the first jaw part. This means that it cannot be detached from the first jaw part without causing damage without using a screwdriver, a wrench or another tool, or even when using a screwdriver, a wrench or another tool, it cannot be detached from the first jaw part without causing damage. A permanent mechanical connection can be achieved, for example, by gluing, soldering, welding or overmolding. Separating the flexible conductor component from the first jaw part by cutting or sawing or by destroying an adhesive or welded connection would not be non-destructive.

Alternatively, the flexible conductor component can be mechanically connected to the first jaw part in such a way that it can be separated from the first jaw part without causing any damage, even without using a screwdriver, a wrench or another tool. For example, the flexible conductor component has a pocket which, when the electrosurgical tool is used as intended, accommodates the first jaw part or part of the first jaw part. Alternatively or additionally, the flexible conductor component can be detachably mechanically connected to the first jaw part, for example by a snap-in connection, for example by one or more snap fasteners. Alternatively or additionally, the flexible conductor component can be detachably mechanically connected to the first jaw part, for example by a dovetail guide or in another form-fitting manner. Alternatively or additionally, the flexible conductor component can be held to the first jaw part, for example by magnetic or electrostatic forces.

The flexible conductor component is in particular a flexible circuit board or a flex board, as used in many electrical or electronic devices. Such a flexible circuit board often comprises one or more films made of polyimide or another plastic. Electrically conductive conductor tracks can be arranged on one or both surfaces of the film. In the case of several polyimide films, electrically conductive conductor tracks can be arranged between them, which can thus be electrically insulated from the environment.

Alternatively, the flexible conductor component can be partially or completely manufactured as a MID (Molded Interconnect Device or Mechatronic Integrated Device).

Flexible conductor components, particularly flexible printed circuit boards or flex boards, are available in a wide variety and at low cost. Both the thickness of the flexible conductor component and the structural sizes of conductor tracks on and in a flexible conductor component, their geometric shape and arrangement can be freely selected within wide limits and can be adapted to the requirements of the application. Flexible conductor components or at least their surfaces can be made of medically safe materials. Insulating distances on and in flexible conductor components can be dimensioned for high voltages. The current-carrying capacity of conductor tracks in flexible conductor components can be adjusted within wide limits.

The use of a flexible conductor component and the formation of electrode surfaces on its surface can represent a cost-effective and technically and medically convincing solution. This applies both to fully reusable electrosurgical tools that can be used again after cleaning and sterilization, and to electrosurgical tools that are partially or completely designed and constructed for single use only. For example, the flexible conductor component can be designed and constructed for single use and the jaw parts and other components of the electrosurgical tool can be designed and constructed for multiple use.

In an electrosurgical tool as described here, in particular at least either the first gripping surface on the first jaw part or the second gripping surface on the second jaw part is flat or substantially flat.

An electrosurgical tool as described here is in particular a gripping tool with several jaw parts that can be moved towards and away from each other manually or by motor.

The electrosurgical tool can have two or more jaw parts, one or more of which are movable, in particular pivotable. The electrosurgical tool can be designed and constructed for gripping, holding and squeezing tissue between the jaw parts.

In an electrosurgical tool as described here, the flexible conductor component in particular comprises a plurality of conductor tracks (76), wherein each of the plurality of conductor tracks is electrically conductively connected to one of the plurality of first electrode surfaces.

The conductor tracks are formed from one or more electrically conductive materials and are electrically insulated from one another and in particular from the surroundings of the flexible conductor component. For this purpose, the conductor tracks can be arranged in the electrically insulating substrate or covered by an electrically insulating material, for example a varnish.

The conductor tracks can merge into the electrode surfaces and can be manufactured in one piece and/or at the same time. For example, an area not covered by electrically insulating material and optionally widened at a distal end of each conductor track forms an electrode surface.

The conductor tracks are intended and designed to connect the electrode surfaces independently of one another to an electrical power source and/or to an electrical measuring device.

An electrosurgical tool as described herein comprises, in particular, a joint which articulates at least one of the first jaw part and the second jaw part to a distal end of a shaft or to a mechanical coupling device or to a handling device, wherein the flexible conductor component extends from the first jaw part across the joint to a location proximal to the joint.

The joint can have one or more degrees of freedom. In particular, the joint enables pivoting about a pivot axis of predetermined spatial orientation relative to one or both jaw parts.

The coupling device is provided and designed in particular for the mechanical connection of the electrosurgical tool to a corresponding coupling device at a distal end of a shaft or at a handling device, which can be released non-destructively even without the use of tools.

The location proximal to the joint to which the flexible conductor component extends is in particular immediately proximal to the joint or at a proximal end of a shaft or in a handling device to which the electrosurgical tool is mechanically and functionally connected.

By extending from the electrode surfaces to a location proximal to the joint, the flexible conductor component with the conductor tracks on or in it can create an electrically conductive connection across the joint.

In an electrosurgical tool as described here, the flexible conductor component extends in particular from the first jaw part through the joint or past the joint to a handling device.

The handling device can be directly mechanically connected to the electrosurgical tool. Alternatively, the handling device can be indirectly mechanically connected to the electrosurgical tool, in particular by a long and thin, straight or curved, rigid or flexible shaft.

Optionally, the flexible conductor component may extend proximally beyond the handling device, for example similar to a cable or within a cable to an electrical power source and/or an electrical measuring device for measuring an impedance and/or another electrical property or characteristic.

In an electrosurgical tool as described here, the flexible conductor component extends in particular from the first jaw part via the joint to a proximal end of a shaft, the distal end of which is mechanically connected to the electrosurgical tool.

Similar to the case of many conventional minimally invasive instruments where a pull or push rod or other mechanical transmission device extends to the handling device, the flexible conductor component can extend to the handling device. This applies regardless of whether the electrosurgical tool is mechanically connected to the shaft permanently or in a non-destructively detachable manner, and regardless of whether the shaft is mechanically connected to the handling device permanently or in a non-destructively detachable manner.

In particular, an electrosurgical tool as described herein includes an electrical connector mechanically and electrically connected to a proximal end of the flexible conductor member.

The electrical connector is in particular an electrical plug connector. The electrical connector in particular is permanently mechanically connected to the flexible conductor component. The proximal end of the flexible conductor component can form part of the electrical connector. In particular, exposed proximal ends of conductor tracks of the flexible conductor component can form contacts of the electrical connector.

In an electrosurgical tool as described here, the proximal end of the flexible conductor component is designed in particular as a connector for mechanical and electrical connection to a corresponding connector or can be mechanically and electrically connected to a connector.

An electrosurgical tool as described here comprises in particular a mechanical transmission device for transmitting a manually or mechanically generated force and/or a manually or mechanically generated torque to the electrosurgical tool for moving at least either the first jaw part or the second jaw part, wherein the flexible conductor component is integrated with the mechanical transmission device or is mechanically rigidly connected.

The mechanical transmission device is provided and designed for the mechanical coupling of the electrosurgical tool to a handling device. This mechanical coupling causes a movement generated manually or mechanically on the handling device to be accompanied by a corresponding movement on the electrosurgical tool. For example, the mechanical transmission device couples a component of the handling device that can be manually pivoted, rotated or moved relative to the rest of the handling device or the proximal end of the shaft to one or more jaw parts of the electrosurgical tool in such a way that every movement of the component relative to the rest of the handling device is accompanied by a movement of the jaw part or parts.

In an electrosurgical tool as described here, the flexible conductor component in the area of the mechanical transmission device is particularly helical.

The flexible conductor component can surround the mechanical transmission device in a screw-shaped or helical manner or can be arranged within the mechanical transmission device. In particular in the case of a flexible mechanical transmission device, a screw-shaped or helical design of the flexible conductor component can ensure that the flexible conductor component offers little mechanical resistance to bending of the transmission device.

An electrosurgical tool as described here comprises in particular a plurality of second electrode surfaces on a second gripping surface on the second jaw part, which are electrically insulated from one another and can be or are connected independently of one another to an electrical power source or an electrical measuring device for measuring an impedance and/or another electrical property or characteristic.

An electrosurgical tool as described here comprises in particular a further flexible conductor component with an electrically insulating substrate and a plurality of second electrode surfaces on a second surface region on the further flexible conductor component, wherein at least a partial region of the further flexible conductor component is mechanically connected to the second jaw part, wherein the second surface region of the flexible conductor component with the plurality of second electrode surfaces forms at least part of a second gripping surface on the second jaw part.

The further flexible conductor component has in particular features, properties and functions of a flexible conductor component of an electrosurgical tool described here. The further flexible conductor component is also in particular flat, i.e. thin and essentially two-dimensional. The second electrode surfaces of the plurality of second electrode surfaces are exposed on the second gripping surface on the second jaw part. This means that each individual second electrode surface of the plurality of second electrode surfaces between the gripping surfaces of the jaw parts can directly mechanically touch tissue held or squeezed and form a conductive contact with them. The second electrode surfaces are in particular electrically insulated from one another and can be connected or connected independently of one another to an electrical power source or an electrical measuring device for measuring an impedance and/or another electrical property or parameter. The further flexible conductor component can be permanently mechanically connected to the second jaw part. Alternatively, the further flexible conductor component can be mechanically connected to the second jaw part in such a way that it can be separated from the second jaw part without causing any damage, even without the use of tools.

In an electrosurgical tool as described here, the flexible conductor component in particular further comprises a plurality of second electrode surfaces on a second surface region on a second partial region of the flexible conductor component, wherein the first partial region of the flexible conductor component comprising the first surface region and the second partial region of the flexible conductor component comprising the second surface region are mechanically connected to the first jaw part.

The first partial area and the second partial area of the flexible conductor component are arranged in particular parallel to one another and on both sides of a bead and/or a groove on the gripping surface of the first jaw part. The bead can be provided and designed to compress gripped tissue. The groove can be provided and designed to guide a mechanical cutting tool between the jaw parts.

In an electrosurgical tool as described here, the flexible conductor component in particular further comprises a plurality of second electrode surfaces on a second surface region on a second partial region of the flexible conductor component, wherein the second partial region of the flexible conductor component comprising the second surface region is mechanically connected to the second jaw part, wherein the second surface region of the flexible conductor component with the plurality of second electrode surfaces forms at least part of a second gripping surface on the second jaw part.

The flexible conductor component can therefore have a first partial area with a plurality of first electrode surfaces, which forms the first gripping surface on the first jaw part, and a second partial area with a plurality of second electrode surfaces, which forms the second gripping surface on the second jaw part. The flexibility of the conductor component enables the movement of the two jaw parts relative to one another.

The second electrode surfaces of the plurality of second electrode surfaces are in particular electrically insulated from one another and can be connected or connected independently of one another to an electrical power source or an electrical measuring device for measuring an impedance and/or another electrical property or characteristic. In particular, all first electrode surfaces of the plurality of first electrode surfaces and all second electrode surfaces of the plurality of second electrode surfaces are electrically insulated from one another and can be connected or connected independently of one another to an electrical power source or an electrical measuring device for measuring an impedance and/or another electrical property or characteristic. Alternatively, within one or more groups, a plurality of first electrode surfaces and/or second electrode surfaces can be connected to one another in parallel.

The second sub-region of the flexible conductor component can be permanently mechanically connected to the second jaw part. This means that it cannot be detached from the second jaw part without causing damage without using a screwdriver, a wrench or another tool, or even cannot be detached from the second jaw part without causing damage when using a screwdriver, a wrench or another tool. Alternatively, the second sub-region of the flexible conductor component can be mechanically connected to the second jaw part in such a way that it can be separated from the second jaw part without causing damage even without using a screwdriver, a wrench or another tool. The mechanical connection between the flexible conductor component and the first jaw part and the mechanical connection between the second sub-region of the flexible conductor component and the second jaw part can be the same or different.

Forming the first gripping surface of the first jaw part and the second gripping surface of the second jaw part using the same flexible conductor component can simplify the manufacture of the electrosurgical tool and, above all, the contacting of the electrode surfaces.

In an electrosurgical tool as described here, the flexible conductor component has in particular a forked shape.

In an electrosurgical tool as described here, the flexible conductor component has in particular a fork-shaped configuration with the first partial area on the first jaw part and the second partial area on the second jaw part.

The first partial area of the flexible conductor component with the first electrode surfaces on the first jaw part thus resembles a first prong, the second partial area of the flexible conductor component with the second electrode surfaces on the second jaw part resembles a second prong of a fork. An elongated section of the flexible conductor component, which can contain conductor tracks for contacting the first and second electrode surfaces and can extend to a handling device, resembles the handle of a fork.

In an electrosurgical tool as described here, in particular at least either the first electrode surfaces or the second electrode surfaces are arranged in strip form and parallel to one another.

In an electrosurgical tool as described here, in particular the first electrode surfaces are arranged in strip form and parallel to one another and the second electrode surfaces are arranged in strip form and parallel to one another and orthogonal to the first electrode surfaces.

In an electrosurgical tool as described here, in particular at least either the first electrode surfaces or the second electrode surfaces are arranged in a periodically repeating pattern in one direction or in multiple directions.

For example, the first electrode surfaces and/or the second electrode surfaces are each arranged in straight strips with constant and equal widths and parallel to one another and at equal distances. Alternatively, the first electrode surfaces and/or the second electrode surfaces each have, for example, the shape of circles, ellipses, rectangles, hexagons or other polygons and are arranged in the form of a rectangular or oblique-angled (in particular hexagonal) grid or an array that is periodic in two directions.

In an electrosurgical tool as described here, in particular the first electrode surfaces are arranged in a first plane or substantially in a first plane and/or the second electrode surfaces are arranged in a second plane or substantially in a second plane.

An electrosurgical instrument includes an electrosurgical tool as described herein.

An electrosurgical instrument comprises an electrosurgical tool as described herein and a handling device that is mechanically and functionally connectable or connected to the tool for manual or mechanical control of functions of the electrosurgical instrument.

An electrosurgical instrument comprises a shaft having a proximal end that is mechanically and functionally coupleable or coupled to a handling device for manual or mechanical control of functions of the electrosurgical instrument, and a distal end and an electrosurgical tool as described herein that is mechanically and functionally coupleable or coupled to the distal end of the shaft.

Optionally, the electrosurgical instrument further comprises a handling device that is or can be mechanically and functionally coupled to the proximal end of the shaft.

A method for producing an electrosurgical tool for an electrosurgical instrument comprises a step of providing a first jaw part, a step of providing a second jaw part, a step of providing a flexible conductor component with an electrically insulating substrate and a plurality of first electrode surfaces on a first surface region on a first partial region of the flexible conductor component and a step of mechanically connecting at least the first partial region of the flexible conductor component to the first jaw part, such that the first surface region with the plurality of first electrode surfaces on the first partial region of the flexible conductor component forms at least part of a first gripping surface on the first jaw part.

The method is used in particular for producing an electrosurgical tool as described here, i.e. with features, properties and functions of the electrosurgical tool described here.

An electrosurgical tool produced by means of the method has in particular features, properties and functions of an electrosurgical tool described here. In particular, a flat flexible conductor component, i.e. a thin and essentially two-dimensional flexible conductor component, is provided. The electrode surfaces of the plurality of first electrode surfaces are exposed on the first gripping surface on the first jaw part. This means that each individual electrode surface of the plurality of first electrode surfaces is between the gripping surfaces of the Jaws can directly mechanically touch tissue held or squeezed and form a conductive contact with it. The electrode surfaces are in particular electrically insulated from one another and can be connected or are connected independently of one another to an electrical power source or an electrical measuring device for measuring an impedance and/or another electrical property or characteristic.

The flexible conductor component can be permanently mechanically connected to the first jaw part. Alternatively, the flexible conductor component can be mechanically connected to the first jaw part in such a way that it can be separated from the first jaw part without the use of tools and without causing any damage.

A method as described here further comprises, in particular, a step of providing a further flexible conductor component with an electrically insulating substrate and a plurality of second electrode surfaces on a second surface region on the further flexible conductor component and a step of mechanically connecting at least a partial region of the further flexible conductor component to the second jaw part, so that the second surface region on the further flexible conductor component forms the second gripping surface on the second jaw part.

The further flexible conductor component also has in particular features, properties and functions of another flexible conductor component of an electrosurgical tool described here.

A method as described here further comprises, in particular, a step of mechanically connecting a further partial region of the flexible conductor component to the second jaw part, so that a second surface region with a plurality of second electrode surfaces on the second partial region of the flexible conductor component forms a second gripping surface on the second jaw part.

In this case, the flexible conductor component is in particular permanently connected to the second jaw part. This means that the flexible conductor component cannot be separated from the second jaw part without causing damage, at least without using a screwdriver, a wrench or another tool. Alternatively, the flexible conductor component is connected to the second jaw part in a way that can be removed without causing damage, for example. The second electrode surfaces on the second partial area of the flexible conductor component are in particular electrically insulated from one another and can be connected independently of one another to an electrical power source or an electrical measuring device.

Short description of the characters

• 1 eine schematische Darstellung eines elektrochirurgischen Instruments;
• 2 eine schematische Darstellung eines elektrochirurgischen Werkzeugs des elektrochirurgischen Instruments aus 1;
• 3 eine schematische Darstellung eines Schnitts durch das elektrochirurgische Werkzeug aus den 1 und 2;
• 4 eine schematische Darstellung einer flexiblen Leiterplatte des elektrochirurgischen Werkzeugs aus den 1 bis 3;
• 5 ein schematisches Flussdiagramm eines Verfahrens zum Herstellen eines elektrochirurgischen Werkzeugs.

In the following, embodiments are explained in more detail using the attached figures. They show:

• 1 a schematic representation of an electrosurgical instrument;
• 2 a schematic representation of an electrosurgical tool of the electrosurgical instrument from 1 ;
• 3 a schematic representation of a section through the electrosurgical tool from the 1 and 2 ;
• 4 a schematic representation of a flexible circuit board of the electrosurgical tool from the 1 to 3 ;
• 5 a schematic flow diagram of a method for manufacturing an electrosurgical tool.

Description of the embodiments

1 shows a schematic representation of an electrosurgical instrument 10. A handling device 12 forms a proximal end of the electrosurgical instrument 10. The handling device 12 has a fixed handle part 14 and a movable relative to the fixed handle part 14, for example about a pivot axis orthogonal to the plane of the drawing of the 1 pivoting handle part 16.

The electrosurgical instrument 10 further comprises a shaft 20. A proximal end 22 of the shaft 20 is mechanically connected to the handling device 12. The mechanical connection between the proximal end 22 of the shaft 20 and the handling device 12 can be permanently or non-destructively detachable.

In the example shown, the distal end 24 of the shaft 20 is formed by a coupling device 26.

The electrosurgical instrument 10 further comprises a transmission device 30 which is arranged in the shaft 20. The transmission device 30 has a proximal end 32 and a distal end 34. The transmission device 30 is provided and designed to transmit a translational movement and a corresponding force and/or a rotational movement and a corresponding torque between its proximal end 32 and its distal end 34.

The electrosurgical instrument 10 further comprises an electrosurgical tool 40. A proximal end 42 of the electrosurgical tool 40 is mechanically connected to the distal end 24 of the shaft 20 in a permanent or non-destructively detachable manner. The electrosurgical tool 40 also includes a joint 44.

In the example shown, a coupling device 46 corresponding to the coupling device 26 at the distal end 24 of the shaft 20 forms the proximal end 42 of the electrosurgical tool 40. The coupling device 26 at the distal end 24 of the shaft 20 and the corresponding coupling device 46 at the proximal end 42 of the electrosurgical tool 40 form a particularly rigid but detachable mechanical connection of the electrosurgical tool 40 to the shaft 20.

The electrosurgical tool 40 comprises a first jaw part 52 and a second jaw part 54. In the example shown, both jaw parts 52, 54 are mechanically connected to the proximal end 42, namely the coupling device 46, by the joint 44. The joint 44 defines a pivot axis orthogonal to the plane of the drawing of the 1 around which both jaw parts 52, 54 can be pivoted.

Alternatively and deviating from the representation in 1 One jaw part 52 can be rigidly connected to the proximal end 42 and the coupling device 46 and only the other jaw part 54 can be pivotally connected. Furthermore, the electrosurgical tool 40 can deviate from the illustration in 1 have more than two jaw parts 52, 54.

The proximal end 32 of the transmission device 30 is mechanically coupled to the movable handle part 16 of the handling device 12. The distal end 34 of the transmission device 30 is connected to the jaw parts 52, 54 of the electrosurgical tool 40 in a 1 mechanically coupled in a manner not shown. Therefore, every movement of the movable handle part 16 of the handling device 12 is accompanied by a movement of the jaw parts 52, 54. A force generated manually or by a machine on the movable handle part 16 is transmitted to the jaw parts 52, 54.

2 shows a schematic and enlarged representation of the electrosurgical tool 40 of the electrosurgical instrument 10 from 1 . The drawing level of the 2 corresponds to the drawing level of the 1 .

The first jaw part 52 has a first gripping surface 56 which faces the second jaw part 54. The second jaw part 54 has a second gripping surface 58 which faces the first jaw part 52. Both gripping surfaces 56, 58 are flat, orthogonal to the plane of the drawing of the 2 and designed in such a way that they can lie flat or essentially flat against each other. Alternatively and deviating from the representation in 2 the gripping surfaces 56, 58 can be bent (Gaussian curvature k = 0) or curved (Gaussian curvature k ≠ 0).

The electrosurgical tool 40 comprises a flexible circuit board 60 with an electrically insulating substrate 64, which can consist of a stack of laminated thin plastic films. The flexible circuit board 60 is thin and flat and in particular initially manufactured in a flat shape and then permanently or detachably mechanically connected to the electrosurgical tool. The flexible circuit board 60 has a fork-shaped topology with a narrow strip-shaped proximal section 70, a first distal section 72 and a second distal section 74. The two distal sections 72, 74 are arranged relative to the proximal section 70 like the tines of a fork relative to its handle.

First conductor tracks 76 and second conductor tracks 78 are arranged in the electrically insulating substrate 64 of the flexible circuit board 60, in particular between the films in the case of a substrate 64 formed from several laminated films. The first conductor tracks 76 extend from the first distal partial region 72 to a proximal end of the proximal partial region 70. The second conductor tracks 78 extend from the second distal partial region 74 to a proximal end of the proximal partial region 70.

The first distal portion 72 of the flexible circuit board 60 is arranged on the first jaw part 52. At least a part of the first distal portion 72 of the flexible circuit board 60 is permanently or detachably mechanically connected to the first jaw part 52, for example by an adhesive or a Velcro connection or by a positive fit. A first surface area 82 on the first distal portion 72 forms the first gripping surface 56 on the first jaw part 52 or - deviating from the illustration in 2 - at least a part of the first gripping surface 56 on the first jaw part 52.

The second distal portion 74 of the flexible circuit board 60 is arranged on the second jaw part 54. At least a part of the second distal portion 74 of the flexible circuit board 60 is permanently or detachably mechanically connected to the second jaw part 52, for example by an adhesive or a Velcro connection or by a positive fit. A second surface area 84 on the second distal portion 74 forms the second gripping surface 58 on the second jaw part 54 or - deviating from the representation in 2 - at least a part of the second gripping surface 58 on the second jaw part 54.

The first surface area 82 on the first distal portion 72 of the flexible circuit board 60 has a plurality of exposed, i.e. open, first electrode surfaces 86. The first electrode surfaces 86 thus form parts of the first gripping surface 56 on the first jaw part 52. The first electrode surfaces 86 can be formed by conductive structures - in particular open areas of first conductor tracks 76 - on the surface of the electrically insulating substrate 64.

The first electrode surfaces 86 can be as in 2 indicated be raised relative to the areas of the first gripping surface 56 formed by the surface of the electrically conductive substrate 64. Alternatively and deviating from the illustration in 2 the electrically conductive structures that form the first electrode surfaces 86 can be partially or completely embedded in the electrically conductive substrate 64. In this case, the first electrode surfaces 86 protrude less towards the second jaw part 54 than the areas of the first gripping surface 56 formed by the surface of the electrically conductive substrate 64, or are flush with these areas.

Each first electrode surface 86 is electrically conductively connected to a distal end of a first conductor track 76. In particular, each first electrode surface 86 is formed on a first conductor track 76 or on an electrically conductive structure that is formed integrally or monolithically with a first conductor track 76 and/or merges into it. Each first conductor track 76 can be electrically conductively connected to a first electrode surface 86 or to several first electrode surfaces 86 (thus connected electrically in parallel).

The second surface area 84 on the second distal portion 74 of the flexible circuit board 60 has a plurality of exposed, i.e. open, second electrode surfaces 88. The second electrode surfaces 88 thus form parts of the second gripping surface 58 on the second jaw part 54. The second electrode surfaces 88 can be formed by conductive structures - in particular open areas of second conductor tracks 78 - on the surface of the electrically insulating substrate 64.

The second electrode surfaces 88 can be as in 2 indicated be raised relative to the areas of the second gripping surface 58 formed by the surface of the electrically conductive substrate 64. Alternatively and deviating from the illustration in 2 the electrically conductive structures that form the second electrode surfaces 88 can be partially or completely embedded in the electrically conductive substrate 64. In this case, the second electrode surfaces 88 protrude less towards the first jaw part 52 than the areas of the second gripping surface 58 formed by the surface of the electrically conductive substrate 64, or are flush with these areas.

Each second electrode surface 88 is electrically conductively connected to a distal end of a second conductor track 78. In particular, each second electrode surface 88 is formed on a second conductor track 78 or on an electrically conductive structure that is integrally or monolithically formed with a second conductor track 78 and/or merges into it. Each second conductor track 78 can be electrically conductively connected to a second electrode surface 88 or to several second electrode surfaces 88 (thus electrically connected in parallel).

In the area of the joint 44 of the electrosurgical jaw part 40 and proximal to it, the distal sub-areas 72, 74 and the proximal sub-area 70 of the flexible circuit board 60 are hidden inside the joint 44 and inside the shaft 20 and are therefore not visible from the outside. Therefore, the distal sub-areas 72, 74 and the proximal sub-area 70 of the flexible circuit board 60 inside the joint 44 and inside the shaft 20 are shown by dashed lines.

In the example shown, the distal portions 72, 74 of the flexible circuit board 60 are bent in the region of the joint 44 of the electrosurgical jaw part 40 in order to generate increased elasticity. This increased elasticity facilitates the pivoting of the jaw parts 52, 54 about the pivot axis defined by the joint 44 and the bending of the distal portions 72, 74 of the flexible circuit board 60 required in this process. Furthermore, this increased elasticity enables the changes in the distances bridged by the distal portions 72, 74 caused by the pivoting.

The proximal portion 70 of the flexible circuit board 60 is arranged in the shaft 20. In the example shown, the proximal portion 70 of the flexible circuit board 60 is mechanically rigidly connected to the transmission device 30 and partially surrounds it in the circumferential direction.

3 shows a schematic representation of a section through the electrosurgical tool 40 from the 1 and 2 . The cutting plane is orthogonal to the drawing planes of the 1 and 2 and lies between the joint 44 and the proximal end 42 of the electrosurgical tool 40 formed by the coupling device 46. The position of the cutting plane III-III of the 3 is in 2 indicated. A section through the shaft 20 would look similar.

In the example shown, the transmission device 30 is rod-shaped with a circular cross-section. The proximal partial area 70 of the flexible circuit board 60 largely surrounds the transmission device 30 in the circumferential direction, i.e. has a C-shaped cross-section. The proximal partial area 70 of the flexible circuit board 60 is connected to the outer surface of the transmission device 30, in particular over a large area, for example by gluing. The flexible circuit board 60 can be arranged parallel to the transmission device 30 or can surround it helically in order to offer only a small resistance to bending of the transmission device 30.

The first conductor tracks 76 and the second conductor tracks 78 are arranged in the electrically conductive substrate 64. The conductor tracks 76, 78 are electrically insulated from one another and from the environment, in particular from the shaft 20 and from the transmission device 30, by the electrically insulating substrate 64.

Alternatively and deviating from the representation based on the 2 and 3 the proximal portion 70 of the flexible circuit board 60 may not be mechanically connected to the transmission device 30, but rather to the inner surface of the tube forming the shaft 20. Furthermore, the proximal portion 70 of the flexible circuit board 60 may not be mechanically connected to the transmission device 30 or to the tube forming the shaft 20.

4 shows a schematic representation of a top view of the flexible circuit board 60 of the electrosurgical tool 40 from the 1 to 3 . 4 shows the flexible circuit board 60 in a flat shape, as it is present in particular immediately after the production of the flexible circuit board 60. The drawing plane of the 4 is parallel to the two large and in the 4 shown configuration flat surface areas of the flexible circuit board 60. The electrically insulating substrate 64 of the flexible circuit board 60 can be optically transparent or opaque or largely or completely opaque. Therefore, the contours of the first and second conductor tracks 76, 78 inside the electrically insulating substrate 64 are indicated by dashed lines.

The flexible circuit board 60 has a fork-shaped topology in which the narrow strip-shaped proximal portion 70 resembles the handle and the distal portions 72, 74 resemble the tines of a fork.

At the proximal end 62 of the proximal portion 70 of the flexible circuit board 60, there is a multi-pin connector 90 for the detachable mechanical and electrical connection of the flexible circuit board 60 and its conductor tracks 76, 78 with a corresponding connector in or on the handling device 12 (cf. 1 ) or with a cable. Impedances and/or other electrical properties or characteristics between pairs of electrode surfaces 86, 88 or other electrical measurements can be recorded or electrical voltages can be applied to pairs of electrode surfaces 86, 88 via the connector 90.

Alternatively and deviating from the representation based on the 1 to 4 the flexible circuit board 60 can have only one (particularly strip-shaped) distal part area, which only forms the first gripping surface 56 of the first jaw part 52. This first jaw part 52 can be connected rigidly or movably by a joint 44 to the proximal end 42 of the electrosurgical tool 40. The second gripping surface 58 of the second jaw part 54 can have second electrode surfaces 88, which are not formed by the flexible circuit board 60, however. The second electrode surfaces 88 can be formed, for example, on a distal part area of another flexible circuit board, which forms the second gripping surface 58 on the second jaw part 54.

The transmission device 30 is in particular connected in an articulated but permanent manner mechanically to the electrosurgical tool 40, namely to its jaw parts 52, 54. After releasing the mechanical connection between the coupling device 26 at the distal end 24 of the shaft 20 and the corresponding coupling device 46 at the proximal end 42 of the electrosurgical tool 40, the transmission device 30 can be pulled distally out of the tube forming the shaft 20. The same applies to the proximal portion 70 of the flexible circuit board.

Alternatively and deviating from the representation based on the 1 to 4 the electrosurgical tool 40 can be permanently mechanically connected to the distal end 24 of the shaft 20.

5 shows a schematic flow diagram of a method for producing an electrosurgical tool. The method is particularly suitable for producing the 1 to 3 However, the method is also suitable for producing an electrosurgical tool with features, properties and functions that differ from those described in the 1 to 4 shown, Nevertheless, exemplary reference symbols from the 1 to 3 used.

In a first step 101, a first jaw part 52 is provided. In a second step 102, a second jaw part 54 is provided. In a third step 103, a flexible conductor component, in particular a flexible circuit board 60 with a proximal partial region 70, one or more (in particular distal) partial regions 72, 74, first electrode surfaces 86 on a first surface region 82 on the first partial region 72 and optionally second electrode surfaces 88 on a second surface region 84 on a second distal partial region 74 is provided.

In a fourth step 104, the first partial region 72 of the flexible conductor component 60 is permanently or detachably mechanically connected to the first jaw part 52, so that the first surface region 82 on the first partial region 72 of the flexible conductor component 60 forms the first gripping surface 56 on the first jaw part 52.

In an optional fifth step 105, the second partial region 74 of the flexible conductor component 60 is permanently or detachably mechanically connected to the second jaw part 54, so that the second surface region 84 on the second partial region 74 of the flexible conductor component 60 forms the second gripping surface 58 on the second jaw part 54.

Reference symbols

10

electrosurgical instrument

12

Handling device of the electrosurgical instrument 10

14

fixed handle part of the handling device 12

16

movable handle part of the handling device 12

20

Shaft of the electrosurgical instrument 10

22

proximal end of shaft 20

24

distal end of shaft 20

26

Coupling device at the distal end 24 of the shaft 20, for detachable mechanical connection with the electrosurgical tool 40

30

Transmission device in the shaft 16

32

proximal end of the transmission device 30

34

distal end of the transmission device 30

40

electrosurgical tool of the electrosurgical instrument 10

42

proximal end of the electrosurgical tool 40

44

Joint of the electrosurgical tool 40

46

Coupling device at the proximal end 42 of the electrosurgical tool 40

52

first jaw of the electrosurgical tool 40

54

second jaw of the electrosurgical tool 40

56

first gripping surface on the first jaw part 52

58

second gripping surface on the second jaw part 54

60

flexible circuit board of the electrosurgical tool 40

62

proximal end of the flexible circuit board 60

64

electrically insulating substrate of the flexible circuit board 60

66

electrical connector at the proximal end 62 of the flexible circuit board 60

70

proximal part of the flexible circuit board 60

72

first distal portion of the flexible circuit board 60

74

second distal portion of the flexible circuit board 60

76

first conductor tracks in the flexible circuit board 60

78

second conductor tracks in the flexible circuit board 60

82

first surface area on the first distal portion 72 of the flexible circuit board 60

84

second surface area on the second distal portion 74 of the flexible circuit board 60

86

first electrode surface on the first surface area 76 of the flexible circuit board 60

88

second electrode surface on the second surface area 78 of the flexible circuit board 60

90

multi-pin connector

101

First step (providing a first jaw part)

102

Second step (providing a second jaw part)

103

Third step (providing a flexible conductor component)

104

fourth step (mechanical connection of a first part of the flexible conductor component with the first jaw part)

105

fifth step (mechanical connection of a second part of the flexible conductor component with the second jaw part)

QUOTES INCLUDED IN THE DESCRIPTION

This list of documents listed by the applicant was generated automatically and is included solely for the better information of the reader. The list is not part of the German patent or utility model application. The DPMA accepts no liability for any errors or omissions.

Cited patent literature

• EP 1632192 A1 [0003]
• US 20070156139 A1 [0004]
• US 7776036 B2 [0004]
• US 2010274244 A1 [0005]
• US 8277446 A1 [0005]
• US 2016/0287316 A1 [0006]
• US 10813684 B2 [0006]
• US 2016/0302854 A1 [0007]
• US 9717550 B2 [0007]
• EP 2149342 A1 [0008]

Claims (13)

Electrosurgical tool (40) for an electrosurgical instrument (10), comprising: a first jaw part (52); a second jaw part (54); a flexible conductor component (60) with an electrically insulating substrate (64) and a plurality of first electrode surfaces (82) on a first surface region (82) of the flexible conductor component (60), wherein at least a first partial region (72) of the flexible conductor component (60) is mechanically connected to the first jaw part (52), wherein the first surface region (82) of the flexible conductor component (60) with the plurality of first electrode surfaces (86) forms at least part of a first gripping surface (56) on the first jaw part (52). Electrosurgical tool (40) according to the preceding claim, in which the flexible conductor component (60) comprises a plurality of conductor tracks (76), each of the plurality of conductor tracks (76) is electrically conductively connected to one of the plurality of first electrode surfaces (86). Electrosurgical tool (40) according to one of the preceding claims, further comprising: a joint (44) which articulates at least one of the first jaw part (52) and the second jaw part (54) to a distal end (24) of a shaft (20) or to a mechanical coupling device (46) or to a handling device (12), wherein the flexible conductor component (60) extends from the first jaw part (52) over the joint (44) to a location proximal to the joint (44). Electrosurgical tool (40) according to the preceding claim, wherein the flexible conductor component (60) extends from the first jaw part (52) through the joint (44) or past the joint (44) to a handling device (12). Electrosurgical tool (40) according to one of the preceding claims, wherein the flexible conductor component (60) extends from the first jaw part (52) via the joint (44) to a proximal end (22) of a shaft (20), the distal end (26) of which is mechanically connected to the electrosurgical tool (20). An electrosurgical tool (40) according to any preceding claim, further comprising: an electrical connector (66) mechanically and electrically connected to a proximal end (62) of the flexible conductor member (60). Electrosurgical tool (40) according to one of the preceding claims, further comprising: a mechanical transmission device (30) for transmitting at least one of a manually or mechanically generated force or a manually or mechanically generated torque to the electrosurgical tool (40) for moving at least one of the first jaw part (52) and the second jaw part (54), wherein the flexible conductor component (60) is integrated with the transmission device (30) or is mechanically rigidly connected. Electrosurgical tool (40) according to the preceding claim, wherein the flexible conductor component (60) is helical in the region of the mechanical transmission device (30). Electrosurgical tool (40) according to one of the preceding claims, in which the flexible conductor component (60) further comprises a plurality of second electrode surfaces (88) on a second surface region (84) on a second partial region (74) of the flexible conductor component (60), the second partial region (74) of the flexible conductor component (60), which comprises the second surface region (84), is mechanically connected to the second jaw part (54), the second surface region (84) of the flexible conductor component (60) with the plurality of second electrode surfaces (88) forms at least part of a second gripping surface (58) on the second jaw part (54). Electrosurgical tool (40) according to one of the preceding claims, wherein the flexible conductor component (60) has a forked shape [topology] with the first portion (72) on the first jaw part (52) and the second portion (74) on the second jaw part (54). Electrosurgical instrument (10), comprising: a shaft (20) with a proximal end (22) which can be or is mechanically and functionally coupled to a handling device (12) for manual or mechanical control of functions of the electrosurgical instrument (10), and a distal end (24); an electrosurgical tool (40) according to one of the preceding claims, which can be or is mechanically and functionally coupled to the distal end (24) of the shaft (20). Method for producing an electrosurgical tool (40) for an electrosurgical instrument (10), comprising the following steps: providing (101) a first jaw part (52); providing (102) a second jaw part (54); providing (103) a flexible conductor component (60) with an electrically insulating substrate (64) and a plurality of first electrode surfaces (86) on a first surface region (82) on a first partial region (72) of the flexible conductor component (60); mechanically (104) connecting at least the first partial region (72) of the flexible conductor component (60) to the first jaw part (52) to form at least a portion of the first gripping surface (56), such that the first surface region (82) of the flexible conductor component (60) with the plurality of first electrode surfaces (86) forms at least a portion of a first gripping surface (56) on the first jaw part (52). Method according to the preceding claim, further comprising the following step: mechanically connecting (105) a second partial region (74) of the flexible conductor component (60) to the second jaw part (54), so that a second surface region (84) with a plurality of second electrode surfaces (88) on the second partial region (74) of the flexible conductor component (60) forms a second gripping surface (58) on the second jaw part (54).

Images