Layered ferromagnetic coated conductor thermal surgical tool

• US 10,149,712 B2
• Filed: 07/21/2015
• Issued: 12/11/2018
• Est. Priority Date: 04/17/2009
• Status: Active Grant

• Current Assignee: Domain Surgical, Inc (OmniGuide Holdings, Inc.)
• Original Assignee: Domain Surgical, Inc (OmniGuide Holdings, Inc.)
• Inventors: Manwaring, Kim, Eggers, Philip, Stringham, Mark, Hammond, Paul, McNally, David J.
• Primary Examiner(s): Della, Jaymi
• Application Number:
  US14/804,343
• Publication Number:
  US 20160030103A1
• Time in Patent Office: 1,239 Days
• CPC Class Codes: A61B 18/082 Probes or electrodes therefor
• CPC Class Codes: A61B 18/10 Power sources therefor
• CPC Class Codes: A61B 18/1442 Probes having pivoting end effectors, e.g. forceps
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2018/00107 Coatings on the energy applicator
• CPC Class Codes: A61B 2018/00148 with metal
• CPC Class Codes: A61B 2018/00601 Cutting
• CPC Class Codes: A61B 2018/00642 with feedback, i.e. closed loop control
• CPC Class Codes: A61B 2018/1407 Loop
• CPC Class Codes: A61B 2018/1412 Blade
• CPC Class Codes: A61B 2018/1417 Ball
• CPC Class Codes: C23C 28/02 only coatings only including layers of metallic material

Abstract

A thermal surgical tool comprising a conductor having a ferromagnetic material attached thereto is provided. The conductor may include a support of sufficiently high Young'"'"'s modulus to resist bending when the surgical tool is being used to treat tissue. One or more intervening layers may be disposed between the support and the ferromagnetic material. Each of the intervening layers may be selected for a property that facilitates construction of the surgical tool and/or enhances a functionality of the surgical tool. The thermal surgical tool can be used for separating tissue, coagulation, tissue destruction or achieving other desired tissue effects in numerous surgical procedures.

Claims

1. A method for manufacturing a thermal surgical tool comprising:

forming an electrical conductor by attaching an electrically conductive intervening layer to a metallic support; and

coating the electrical conductor with a ferromagnetic material by electroplating;

wherein the intervening layer is disposed between the metallic support and the ferromagnetic coating.

2. The method according to claim 1, further comprising providing the electrical conductor with connection sites for connecting the electrical conductor to a power source independent of the ferromagnetic material.

3. The method according to claim 1, further comprising disposing an exterior layer over the ferromagnetic material and at least a portion of the electrical conductor.

4. The method according to claim 1, comprising:

disposing a second intervening layer between the metallic support and the electrically conductive intervening layer, wherein the second intervening layer comprises a strike layer that extends substantially a full length of the metallic support.

5. The method of claim 4 wherein attaching the electrically conductive intervening layer to the metallic support includes electroplating the electrically conductive intervening layer to the metallic support.

6. The method of claim 5 wherein the strike layer includes at least one of nickel or gold.

7. The method according to claim 1, wherein the metallic support is at least partially hollow.

8. The method according to claim 7, wherein the metallic support has a coefficient of thermal expansion which is less than a coefficient of thermal expansion of the ferromagnetic material, and a coefficient of thermal expansion of the intervening layer is greater than the coefficient of thermal expansion of the support and less than the coefficient of thermal expansion of the ferromagnetic material.

9. The method according to claim 1, wherein the ferromagnetic material extends a length along the metallic support, the length of the ferromagnetic material being less than about 90 percent of a length of the metallic support.

10. The method according to claim 1, comprising:

disposing a first sleeve on a first end of the metallic support; and

disposing a second sleeve on a second end of the metallic support, the first sleeve and the second sleeve being in electrical communication with the electrically conductive intervening layer.

11. The method according to claim 1, wherein the metallic support has a diameter within a range of 500 μ

m to 750 μ

m, the electrically conductive intervening layer has a thickness within a range of 20 μ

m to 50 μ

m, and the ferromagnetic material has a thickness within a range of 2 μ

m to 10 μ

m.

12. The method according to claim 1, wherein the metallic support has a Young'"'"'s modulus in excess of 17 psi.

13. The method according to claim 1, wherein the metallic support has a Young'"'"'s modulus greater than about 58 psi.

14. The method of claim 1 wherein the metallic support comprises at least one of tungsten, titanium, stainless steel, or an alloy thereof.

15. The method of claim 1, comprising:

electrically connecting a first end of the electrical conductor to a printed circuit board at a first position; and

electrically connecting a second end of the electrical conductor to the printed circuit board at a second position.

17. The method according to claim 2, comprising:

electrically connecting the electric power source to the electrical conductor; and

supplying the oscillating electrical energy to the conductor.

18. The method according to claim 17, wherein a majority of the oscillating electrical energy passes through the electrically conductive intervening layer.

16. A method of treating tissue comprising:

selecting a thermal surgical tool comprising a conductor having a metallic support and an electrically conductive intervening layer on the metallic support, the thermal surgical tool further including a coating of a ferromagnetic material electroplated on the conductor, wherein the conductor is connectable to an electric power source independent of the ferromagnetic material;

disposing the ferromagnetic material adjacent to the tissue;

treating the tissue by directing oscillating electrical energy through the conductor to cause the ferromagnetic material to inductively heat;

wherein the electrically conductive intervening layer is disposed between the metallic support and the ferromagnetic material.