Non-stick coated electrosurgical instruments and method for manufacturing the same

• US 10,441,349 B2
• Filed: 10/24/2016
• Issued: 10/15/2019
• Est. Priority Date: 10/29/2015
• Status: Active Grant

• Current Assignee: Covidien LP (Medtronic Plc)
• Original Assignee: Covidien LP (Medtronic Plc)
• Inventors: Sartor, Joe D., Robinson, William E., Boucher, Todd W.
• Primary Examiner(s): Peffley, Michael F
• Application Number:
  US15/332,797
• Publication Number:
  US 20170119456A1
• Time in Patent Office: 1,086 Days
• CPC Class Codes: A61B 18/1442 Probes having pivoting end effectors, e.g. forceps
• CPC Class Codes: A61B 18/1445 at the distal end of a shaft, e.g. forceps or scissors at the end of a rigid rod
• CPC Class Codes: A61B 2018/00083 low, i.e. electrically insulating
• CPC Class Codes: A61B 2018/00107 Coatings on the energy applicator
• CPC Class Codes: A61B 2018/0013 non-sticking
• CPC Class Codes: A61B 2018/00136 with polymer
• CPC Class Codes: A61B 2018/00148 with metal
• CPC Class Codes: A61B 2018/0063 Sealing
• CPC Class Codes: A61B 2018/162 located on the probe body
• CPC Class Codes: A61B 2034/2059 Mechanical position encoders
• CPC Class Codes: A61B 2034/2061 using shape-sensors, e.g. fiber shape sensors with Bragg gratings
• CPC Class Codes: A61B 2034/2065 Tracking using image or pattern recognition

Abstract

An end effector assembly for use with an electrosurgical instrument is provided. The electrosurgical instrument includes a handle having a shaft that extends therefrom, an end effector disposed at a distal end of the shaft, at least one electrode operably coupled to the end effector and adapted to couple to a source of electrosurgical energy, a titanium nitride coating covering at least a portion of the electrode, a chromium nitride coating covering at least a portion of the electrode and/or titanium nitride coating, and a hexamethyldisiloxane plasma coating covering at least a portion of the chromium nitride coating.

Claims

1. An electrosurgical instrument, comprising:

a handle having a shaft that extends therefrom;

an end effector disposed at a distal end of the shaft, the end effector including;

a support base; and

at least one electrode assembled to the support base and adapted to couple to a source of electrosurgical energy;

a titanium nitride coating covering at least a portion of the electrode;

a chromium nitride coating covering at least a portion of the electrode; and

a hexamethyldisiloxane plasma coating covering an entirety of an outer surface of the end effector including an outer surface of the support base and the at least one electrode including at least a portion of the chromium nitride coating.

2. The electrosurgical instrument according to claim 1, wherein the end effector includes a pair of opposing jaw members, at least one of the jaw members including an electrical jaw lead, the electrode coupled to the electrical jaw lead and the support base.

3. The electrosurgical instrument according to claim 1, wherein the electrode includes a stainless steel layer and wherein a hexamethyldisiloxane plasma coating is disposed over at least a portion of the stainless steel layer.

4. The electrosurgical instrument according to claim 3, further comprising an electrically insulative layer disposed on at least a portion of an underside of the stainless steel layer.

5. The electrosurgical instrument according to claim 4, wherein the electrically insulative layer is formed from a material selected from the group consisting of a polyimide, polycarbonate, and polyethylene.

6. The electrosurgical instrument according to claim 1, wherein the chromium nitride coating is disposed over at least a portion of the titanium nitride coating.

7. An end effector assembly including a pair of opposing jaw members, each of the jaw members comprising:

a support base;

an electrical jaw lead;

a sealing plate coupled to the electrical jaw lead and the support base, the sealing plate having a stainless steel layer;

a titanium nitride coating disposed over at least a portion of the stainless steel layer;

a chromium nitride coating disposed over at least a portion of the stainless steel layer; and

a hexamethyldisiloxane plasma coating disposed over an entirety of an outer surface of the jaw member including an outer surface of the support base and the sealing plate including the chromium nitride coating.

8. The end effector assembly according to claim 7, further comprising an electrically insulative layer disposed on at least a portion of an underside of the stainless steel layer.

9. The end effector assembly according to claim 8, wherein the electrically insulative layer is formed from a material selected from the group consisting of a polyimide, polycarbonate, and polyethylene.

10. The end effector assembly according to claim 7, further comprising an insulative housing disposed around the support base, wherein the hexamethyldisiloxane plasma coating is disposed on the sealing plate and the insulative housing.

11. The end effector assembly according to claim 7, wherein the chromium nitride coating is disposed over at least a portion of the titanium nitride coating.

12. A method of manufacturing an electrosurgical instrument, comprising:

applying a titanium nitride coating to at least a portion of an electrically conductive surface;

applying a chromium nitride coating to at least a portion of an electrically conductive surface to form a coated electrically conductive surface;

assembling the coated electrically conductive surface to a treatment member by affixing the coated electrically conductive surface to a support base to form an assembled treatment member; and

applying a hexamethyldisiloxane plasma coating over at least a portion of the assembled treatment member including both of the electrically conductive surface and the support base.

13. The method according to claim 12, wherein the assembling the coated electrically conductive surface to the treatment member includes:

providing the support base to support the electrically conductive surface; and

bonding an electrically insulative layer to an underside of the electrically conductive surface.

14. The method according to claim 13, further comprising overmolding an insulative material about the support base to secure the electrically conductive surface thereto.

15. The method according to claim 12, further comprising forming the electrically conductive surface by stamping the electrically conductive surface from a sheet of stainless steel.

16. The method according to claim 12, further comprising coupling an electrical lead to the electrically conductive surface, the electrical lead configured to connect the electrically conductive surface to an energy source.

17. The method according to claim 12, further comprising applying a chromium nitride coating over the titanium nitride coating.