A medical device includes a body and at least one electrode disposed thereon. The electrode includes a metallic substrate, such as a platinum group metal, an alloy of platinum group metals, or gold. The surface of the substrate is modified in a manner that increases its effective surface area without inducing bulk heating. For example, the surface of the substrate can be laser textured and/or coated, such as with titanium nitride or iridium oxide.

Electrosurgical devices are shown with a coated electrode. Electrosurgical devices and methods of use are shown to apply a consistent delta of energy to a tissue, in contrast to merely applying energy until an ending value is reached. Electrosurgical devices and methods of use are shown to meet the challenges of applying a consistent delta of energy by adjusting a baseline value.

A method for fabricating a medical device includes providing a metal electrode to be used in applying electrical energy to biological tissue and specifying a frequency at which the electrical energy is to be applied. A thickness of a ceramic coating to be applied to the metal electrode is identified so as to reduce an electrical impedance between the metal electrode and the tissue at the specified frequency by a specified amount. The ceramic coating is deposited over the metal electrode to the identified thickness, and the metal electrode is assembled onto a probe for application to the biological tissue.

A surgical instrument comprising a motor assembly, a shaft defining a shaft axis, a distal head, a rotary drive member, and a distal head lock member movable between a first position where the distal head is unlocked from the shaft and a second position where the distal head is locked to the shaft is disclosed. The motor assembly comprises a motor and a controller configured to operate the motor in first and second operating modes. The distal head comprises an end effector movable between an open configuration and a closed configuration. The distal head is rotated about the shaft axis when the distal head lock member is in the first position and the rotary drive member is actuated. The end effector is moved from the open configuration toward the closed configuration when the distal head lock member is in the second position and the rotary drive member is actuated.

A medical device includes a body and at least one electrode disposed thereon. The electrode includes a metallic substrate, such as a platinum group metal, an alloy of platinum group metals, or gold. The surface of the substrate is modified in a manner that increases its effective surface area without inducing bulk heating. For example, the surface of the substrate can be laser textured and/or coated, such as with titanium nitride or iridium oxide.

A surgical system comprising a generator and a surgical instrument configured to receive power from the generator is disclosed. The surgical instrument comprises a housing, a shaft defining a longitudinal axis, an end effector, and an internal charge accumulator. The housing comprises a motor. The end effector is operably responsive to actuations from the electric motor, transitionable between an open and closed configuration, and rotatable about an articulation axis transverse to the longitudinal axis. The generator is incapable of supplying a sufficient power directly to the motor to perform the actuations. The internal charge accumulator is in electric communication with the generator and supplies power to the motor. The internal charge accumulator is chargeable by the generator to a threshold value at a charge rate dependent on a charge level of the internal charge accumulator. The charge rate is independent of a charge expenditure by the surgical instrument.

An electrode for the electrosurgical end effector of a surgical instrument is manufactured by laser etching or roughening an area of the electrode's surface. This provides an area to which an insulating stop may be attached. Beneficially, the roughened area provides a good bond between the insulating stop and the electrode, allowing a greater potential use-life for the surgical instrument. Compared to conventional methods, using a laser reduces costs, increases manufacturing flexibility and allows precise control over the creation of the roughened area.

A medical device including an elongate body having a proximal portion and a distal portion. A plurality of active electrodes is coupled to the distal portion of the elongate body and being configured to electrically couple to a source of pulsed electric field energy. At least one passive electrode is coupled to the elongate body and is not configured to electrically couple to the source of pulsed electric field energy, the at least one passive electrode being configured to passively extend or focus an electric field generated by the plurality of active electrodes.

A surgical system comprising a generator and a surgical instrument configured to receive power from the generator is disclosed. The surgical instrument comprises a housing, a shaft defining a longitudinal axis, an end effector, and an internal charge accumulator. The housing comprises a motor. The end effector is operably responsive to actuations from the electric motor, transitionable between an open and closed configuration, and rotatable about an articulation axis transverse to the longitudinal axis. The generator is incapable of supplying a sufficient power directly to the motor to perform the actuations. The internal charge accumulator is in electric communication with the generator and supplies power to the motor. The internal charge accumulator is chargeable by the generator to a threshold value at a charge rate dependent on a charge level of the internal charge accumulator. The charge rate is independent of a charge expenditure by the surgical instrument.

An electrosurgical instrument comprising a housing, a shaft extending from the housing, an end effector extending from the shaft, an articulation joint rotatably connecting the end effector to the shaft, and a wiring circuit is disclosed. The housing comprises a printed control board. The wiring circuit extends from the printed control board through the shaft and into the end effector. The wiring circuit is configured to monitor a function of the end effector and communicate the monitored function to the printed control board. The wiring circuit comprises a proximal rigid portion fixed to the shaft, a distal rigid portion fixed to the end effector, and an intermediate portion extending from the proximal rigid portion to the distal rigid portion. The intermediate portion comprises a resilient portion and a stretchable portion.