Universal self-limiting electrosurgical return electrode

• US 10,085,791 B2
• Filed: 12/26/2014
• Issued: 10/02/2018
• Est. Priority Date: 12/26/2013
• Status: Active Grant

• Current Assignee: Megadyne Medical Products Incorporated (Johnson & Johnson)
• Original Assignee: Megadyne Medical Products Incorporated (Johnson & Johnson)
• Inventors: Ehninger, Michael D., Borgmeier, Paul R., Greep, Darcy W., Millis, Roger, Fischer, Melissa K.
• Primary Examiner(s): Dvorak, Linda
• Assistant Examiner(s): Clark, Ryan T
• Application Number:
  US14/583,315
• Publication Number:
  US 20150182280A1
• Time in Patent Office: 1,376 Days
• Field of Search: 606 32
• CPC Class Codes: A61B 18/1233 with circuits for assuring patient safety
• CPC Class Codes: A61B 18/16 Indifferent or passive electrodes for grounding
• CPC Class Codes: A61B 2018/167 Passive electrodes capacitively coupled to the skin

Abstract

A self-limiting electrosurgical return electrode for use with electrosurgical procedures is disclosed. The return electrode includes a conductive element and pads disposed on opposing sides of the conductive element. The conductive element, optionally in combination with the pads, is configured to limit the density of electrical current that passes from a patient to the return electrode. The conductive element and the pads can cooperate to define two separate working surfaces on opposing sides of the return electrode. The return electrode can also be safely used with patients of substantially any size and without requiring adjustments to the power settings of an electrosurgical generator.

Claims

1. A reversible safety electrosurgical return electrode comprising:

a conductive element configured to conduct electrical current, the conductive element having a first planar major surface and an opposing second planar major surface, the first planar major surface and the second planar major surface facing in opposite directions from one another;

a first pad positioned adjacent the first planar major surface of the conductive element, wherein the first pad and the conductive element cooperate to define a first working surface of the reversible electrosurgical return electrode on a first side of the reversible electrosurgical return electrode; and

a second pad positioned adjacent the second planar major surface of the conductive element such that the conductive element is disposed between and at least partially separates the first pad and the second pad from one another, wherein the second pad and the conductive element cooperate to define a second working surface of the reversible electrosurgical return electrode on a second side of the reversible electrosurgical return electrode opposite to the first side, the first working surface and the second working surface facing in opposite directions from one another,

wherein the reversible electrosurgical return electrode is configured to have either the first working surface or the second working surface positioned toward a patient during an electrosurgical procedure such that either the first working surface or the second working surface is positioned between the patient and the conductive element and such that electrical current can be transferred between the patient and the conductive element through whichever of the first working surface or the second working surface is disposed between the patient and the conductive element.

2. A reversible safety electrosurgical return electrode according to claim 1, wherein the first pad comprises an inner cover layer and an outer cover layer that define an interior chamber.

3. A reversible safety electrosurgical return electrode according to claim 2, wherein the interior chamber is filled with a material selected from the group consisting of a visco-elastic material, a gel, water, saline, a water based material, a conductive oil, or combinations thereof.

4. A reversible safety electrosurgical return electrode according to claim 2, wherein the inner cover layer is secured to the first planar major surface of the conductive element.

5. A reversible safety electrosurgical return electrode according to claim 1, wherein the second pad comprises an outer cover layer and a fill material.

6. A reversible safety electrosurgical return electrode according to claim 5, wherein edges of the outer cover layer of the second pad are attached to edges of the first pad with the conductive element disposed between the first and second pads.

7. A reversible safety electrosurgical return electrode according to claim 5, wherein the outer cover layer of the second pad and the conductive element at least partially define a second interior chamber in which the fill material of the second pad is disposed.

8. A reversible safety electrosurgical return electrode according to claim 1, wherein the reversible safety electrosurgical return electrode is configured such that electrical current transferred from a patient to the conductive element is transmitted non-uniformly over the portion of the reversible safety electrosurgical return electrode that is contacted by the patient.

9. A reversible safety electrosurgical return electrode according to claim 1, wherein each of the first pad and the second pad has a thickness between about 0.02 inches and about 0.120 inches.

10. A reversible safety electrosurgical return electrode according to claim 1, wherein the reversible safety electrosurgical return electrode is configured to be safely used with patients from multiple industry standard weight categories.

11. A method for safely transferring electrosurgical current in non-uniform current densities from a patient to an electrosurgical return electrode via capacitive coupling, comprising:

passively controlling an impedance of the return electrode, comprising;

providing a plurality of apertures through a conductive element of the electrosurgical return electrode, the plurality of apertures being divided into a first area and a second area, the first area having a first aperture distribution density and the second area having a second aperture distribution density that is different than the first aperture distribution density, each of the first area and the second area having one or more visual indicators to identify and/or distinguish the first area and the second area from one another, wherein;

the first aperture distribution density is configured to transfer electrical current between the conductive element and a patient at a first electrical current density such that the first area is configured for use with patients from a first predetermined category; and

the second aperture distribution density is configured to transfer electrical current between the conductive element and a patient at a second electrical current density such that the second area is configured for use with patients from a second predetermined category; and

positioning a patient on the first area or the second area depending on whether the patient is from the first predetermined category or the second predetermined category.

12. A method according to claim 11, wherein the first aperture distribution density has a lower density of apertures than the second aperture distribution density.

13. A method according to claim 11, wherein the first aperture distribution density has a higher density of apertures than the second aperture distribution density.

14. A method according to claim 11, wherein the plurality of apertures are divided into the first area, the second area, and a third area, the third area having a third aperture distribution density that is different than the first and second aperture distribution densities.

15. A method according to claim 14, wherein the third aperture distribution density is configured to transfer electrical current between the conductive element and a patient at a third electrical current density such that the third area is configured for use with patients from a third predetermined category.