Electrosurgical electrode and method of manufacturing same

• US 10,463,420 B2
• Filed: 04/12/2017
• Issued: 11/05/2019
• Est. Priority Date: 05/12/2005
• Status: Active Grant

• Current Assignee: Innovatech, LLC
• Original Assignee: Innovatech, LLC
• Inventors: Nesbitt, Bruce
• Primary Examiner(s): Peffley, Michael F
• Application Number:
  US15/486,012
• Publication Number:
  US 20170245919A1
• Time in Patent Office: 937 Days
• CPC Class Codes: A61B 17/320016 Endoscopic cutting instruments, e.g. arthroscopes, resectoscopes A61B10/0233, A61B17/29, A61B17/3207 take precedence
• CPC Class Codes: A61B 18/14 Probes or electrodes therefor
• CPC Class Codes: A61B 18/1402 Probes for open surgery
• CPC Class Codes: A61B 2017/0088 ceramic
• CPC Class Codes: A61B 2017/00889 antimicrobial, disinfectant
• CPC Class Codes: A61B 2018/0013 non-sticking
• CPC Class Codes: A61B 2018/00595 Cauterization
• CPC Class Codes: A61B 2018/00607 Coagulation and cutting with the same instrument
• CPC Class Codes: A61B 2018/1412 Blade
• CPC Class Codes: A61B 2018/1417 Ball
• CPC Class Codes: A61B 2018/1425 Needle
• CPC Class Codes: A61B 2018/144 Wire
• CPC Class Codes: B05D 1/06 Applying particulate materials
• CPC Class Codes: B05D 1/12 Applying particulate materials B05D1/06, B05D1/10 take precedence

Abstract

An electrosurgical device coated an epoxy modified rigid silicone powder coating. This coating is applied to the surfaces of an electrosurgical device minimize the build-up of charred tissue (i.e., eschar) on the surfaces of the electrosurgical device.

Claims

1. An electrosurgical electrode comprising:

a conductive substrate including a surface; and

a non-stick coating on a first portion of the surface of the substrate, wherein the non-stick coating includes a plurality of epoxy modified rigid silicone particles each having a size of no greater than one-hundred-fifty microns, and wherein the non-stick coating retains nonstick properties after being heated to up to 850°

F.

2. The electrosurgical electrode of claim 1, wherein the epoxy modified rigid silicone particles at least include:

(a) a solvent-free hydroxyl functional solid phenyl silicone resin;

(b) a calcium metasilicate;

(c) an epoxy cresol novalac resin;

(d) a 60% active powder version of a methyl alkyl polysiloxane;

(e) an o-cresol novolac resin; and

(f) an acrylate copolymer.

3. The electrosurgical electrode of claim 2, wherein:

(a) the solvent-free hydroxyl functional solid phenyl silicone resin is in the range of about 40% to about 60% parts per weight of the coating;

(b) the calcium metasilicate is in the range of about 20% to about 40% parts per weight of the coating;

(c) the epoxy cresol novalac resin is in the range of about 5% to about 15% parts per weight of the coating;

(d) the 60% active powder version of a methyl alkyl polysiloxane is in the range of about 3% to about 7% parts per weight of the coating;

(e) the o-cresol novolac resin is in the range of about 0.5% to about 3% parts per weight of the coating; and

(f) the acrylate copolymer is in the range of about 0.5% to about 3% parts per weight of the coating.

4. The electrosurgical electrode of claim 1, wherein the conductive substrate includes a metal.

5. The electrosurgical electrode of claim 1, wherein a plurality of anti-microbial particles are interspersed in said non-stick coating.

6. The electrosurgical electrode of claim 5, wherein the anti-microbial particles include particles selected from the group consisting of:

silver particles and ceramic particles.

7. The electrosurgical electrode of claim 1, wherein a plurality of electrically conductive particles are interspersed in said non-stick coating.

8. The electrosurgical electrode of claim 1, wherein at least part of the conductive substrate forms a shape selected from the group consisting of:

a blade, a knife, a wire, a needle, a probe and a ball.

9. A medical device comprising:

a substrate including a surface; and

a coating on a first portion of the surface of the substrate, wherein;

the coating includes a plurality of particles each having a size of no greater than one-hundred-fifty microns, and

the coating includes;

a solvent-free hydroxyl functional solid phenyl silicone resin;

a calcium metasilicate;

an epoxy cresol novalac resin;

a 60% active powder version of a methyl alkyl polysiloxane;

an o-cresol novolac resin; and

an acrylate copolymer.

10. The medical device of claim 9, wherein:

(a) the solvent-free hydroxyl functional solid phenyl silicone resin is in the range of about 40% to about 60% parts per weight of the coating;

(b) the calcium metasilicate is in the range of about 20% to about 40% parts per weight of the coating;

(c) the epoxy cresol novalac resin is in the range of about 5% to about 15% parts per weight of the coating;

(d) the 60% active powder version of a methyl alkyl polysiloxane is in the range of about 3% to about 7% parts per weight of the coating;

(e) the o-cresol novolac resin is in the range of about 0.5% to about 3% parts per weight of the coating; and

(f) the acrylate copolymer is in the range of about 0.5% to about 3% parts per weight of the coating.

11. The medical device of claim 9, wherein the substrate includes a metal.

12. The medical device of claim 9, wherein a plurality of anti-microbial particles are interspersed in said coating.

13. The medical device of claim 12, wherein the anti-microbial particles include particles selected from the group consisting of:

silver particles and ceramic particles.

14. The medical device of claim 9, wherein a plurality of electrically conductive particles are interspersed in said coating.

15. The medical device of claim 9, which includes a top coat applied to the coating.

16. The method device of claim 15, wherein said top coat is selected from the group consisting of:

an abrasive resistant coating, a non-stick coating, an anti-microbial coating and an electrically conductive coating.

17. The medical device of claim 9, wherein at least part of the substrate forms a shape selected from the group consisting of:

a blade, a knife, a wire, a needle, a probe and a ball.