Electrosurgical device having a dielectric seal

• US 20020035364A1
• Filed: 09/13/2001
• Published: 03/21/2002
• Est. Priority Date: 09/23/1998
• Status: Active Grant

• Current Assignee: Covidien AG (Medtronic Plc)
• Original Assignee: Sherwood Services AG
• Inventors: Sartor, Joe D., Schoenman, Arthur, Kelm, Vernita
• Granted Patent: US 6,755,825 B2
• Time in Patent Office: Days
• US Class Current: 606/45
• CPC Class Codes: A61B 18/14 Probes or electrodes therefor
• CPC Class Codes: A61B 18/1402 Probes for open surgery
• CPC Class Codes: A61B 2017/00026 Conductivity or impedance, e.g. of tissue
• CPC Class Codes: A61B 2017/00035 pH
• CPC Class Codes: A61B 2017/00057 Light
• CPC Class Codes: A61B 2017/0046 with a releasable handle; with handle and operating part separable for prosthetic joint-implanting tools A61F2/4603
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2018/00178 Electrical connectors
• CPC Class Codes: A61B 2018/00988 Means for storing information, e.g. calibration constants, or for preventing excessive use, e.g. usage, service life counter
• CPC Class Codes: G06M 1/04 for driving the stage of lowest order with variable ratio of drive G06M1/38
• CPC Class Codes: G06M 1/083 by mechanical means counting of stacked objects G06M9/00
• CPC Class Codes: H01H 1/18 with subsequent sliding
• CPC Class Codes: H01H 2300/014 Application surgical instrument
• CPC Class Codes: H01H 9/04 Dustproof, splashproof, drip-proof, waterproof, or flameproof casings
• CPC Class Codes: H01H 9/06 Casing of switch constituted by a handle serving a purpose other than the actuation of the switch, e.g. by the handle of a vacuum cleaner
• CPC Class Codes: H01R 13/66 Structural association with built-in electrical component coupling devices having concentrically or coaxially-arranged contacts H01R24/38
• CPC Class Codes: H01R 2201/12 for medicine and surgery
• CPC Class Codes: H01R 43/26 for engaging or disengaging the two parts of a coupling device structural association with two-part coupling device H01R13/629

Abstract

An electrosurgical device is provided having at least one elastomeric seal capable of providing bio-contamination and dielectric protection by inhibiting the ingress of fluids and contaminants through the nose and actuator areas. The elastomeric seal is manufactured from a thermoplastic elastomer or resin which while in liquid form is placed within a mold. A housing section having the main circuit components and mechanisms of the electrosurgical device is then placed within the mold. Once the elastomer cures, the elastomeric seal seals the components and mechanisms within the housing partial-section. The elastomeric seal defines a flexible first opening at a distal end of the electrosurgical device to accommodate varying diameters of electrodes or blades connected to the nose area of the electrosurgical device. An actuator seal is also provided on the actuator area of the electrosurgical device to prevent fluids and contaminants from entering the electrosurgical device through the actuator area. Two buttons are insert molded within the actuator seal and are operatively associated with a self-cleaning switching mechanism within the housing section to operate the electrosurgical device between a cutting and coagulating mode. The actuator seal is also manufactured from a thermoplastic elastomer or resin. The self-cleaning switching mechanism includes a switch contact plate having pair of movable contacts having contact faces. Each movable contact corresponds to a stationary contact positioned within a circuit mold. As the actuator seal is depressed, contact faces of the movable and stationary contacts slide along each other to clean the contacts from non-conductive corrosion and contaminants. The device is further provided with a plug connector having a counting mechanism for counting the number of times the device is plugged into an electric generator. A disable mechanism is included at the proximal end of the plug connector to disable the device after a pre-determined number of operations.

Claims

1. An electrosurgical device comprising:

a housing having an actuator area and switching mechanism operatively coupled to circuitry;

an actuator positioned in proximity to the actuator area and operatively associated with the switching mechanism for operating the electrosurgical device between a cutting and a coagulating mode; and

a seal overlaying at least a portion of the housing for preventing fluids and contaminants from entering the housing, said seal defining an opening at a distal end of the housing for inserting an electrode therein.

2. The electrosurgical device of claim 1, wherein said actuator is a seal for preventing fluids and contaminants from entering the housing from the actuator area.

3. The electrosurgical device of claim 1, wherein said seal is manufactured from a thermoplastic elastomer.

4. The electrosurgical device of claim 1, wherein said actuator is manufactured from a thermoplastic elastomer.

5. The electrosurgical device of claim 1, wherein said seal includes a lip portion circumferentially surrounding said opening for accommodating varying diameters of electrodes.

6. The electrosurgical device of claim 1, wherein said seal is monolithically formed with said housing.

7. The electrosurgical device of claim 1, wherein said seal is chemically adhered to said electrosurgical device.

8. The electrosurgical device of claim 1, wherein said seal is mechanically attached to said electrosurgical device.

9. The electrosurgical device of claim 1, wherein said switching mechanism includes a pair of moving contacts each corresponding to a stationary contact, wherein one of said moving contacts slides along said corresponding stationary contact upon actuation of said actuator to clean said moving contact and said stationary contact.

10. The electrosurgical device of claim 1, wherein said actuator imparts pressure to a rocker switch of said switching mechanism upon actuation, said rocker switch in turn causes a moving contact to contact a corresponding stationary contact to create an electric circuit between said electrode and an electric generator of which said device is plugged into for performing cutting or coagulating of tissue.

11. The electrosurgical device of claim 1, further comprising a counting mechanism for counting the number of times the electrosurgical device is plugged into an electric generator.

12. The electrosurgical device of claim 11, wherein said counting mechanism includes a disable mechanism for preventing said electrosurgical device from being plugged into the electric generator after a pre-determined amount of insertion and removal operations.

13. The electrosurgical device of claim 11, wherein said counting mechanism includes an indicator for indicating to an operator the number of times the device has been inserted within the electric generator.

15. The method of claim 14, further comprising the step of forming an elastomeric actuator seal around the actuator opening;

16. The method of claim 15, further comprising the step of insert molding two inserts within the actuator seal to identify the cutting and coagulating modes.

17. The method of claim 14, further comprising the step of forming an elastomeric lip portion circumferentially surrounding an opening at a distal end of the electrosurgical device for introducing an electrode therein prior to the step of allowing theelastomer to cure.

19. The elastomeric seal according to claim 18, wherein said elastomeric seal further defines an actuating member pocket for fitting an actuating member of the electrosurgical device therein.

20. The elastomeric seal according to claim 18, wherein said elastomeric seal is manufactured from shore A durometer silicone,

21. The elastomeric seal according to claim 18, wherein said elastomeric seal is manufactured from a thermoplastic elastomer.

22. The elastomeric seal according to claim 18, wherein said lip portion is configured to accommodate varying diameters of electrodes connected to said electrosurgical device.

23. The elastomeric seal according to claim 18, wherein said lip portion has greater elasticity than the body portion .

24. The elastomeric seal according to claim 18, wherein said elastomeric seal is chemically adhered to said electrosurgical device.

25. The elastomeric seal according to claim 18, wherein said elastomeric seal is mechanically attached to said electrosurgical device.

26. The elastomeric seal according to claim 18, wherein said elongated body portion has a uniform thickness.

27. The elastomeric seal according to claim 18, wherein a nose portion at the distal end of the seal has a greater thickness than said body portion.

28. The elastomeric seal according to claim 27, wherein the nose portion has an internal diameter less than the internal diameter of the body portion.

29. The elastomeric seal according to claim 28, wherein the lip portion has an internal diameter less than the internal diameter of the nose portion.

14. A method of manufacturing a seal on an electrosurgical device, said method comprising the steps of:

placing components of the electrosurgical device within an elongated housing section, said housing section including an actuator opening;

introducing the housing section within a mold filled with a liquid thermoplastic elastomer; and

allowing the elastomer to cure and become integral with the housing to seal the components within the housing section.

18. An elastomeric seal for inhibiting the ingress of bio-materials into an electrosurgical device of the type having an electrode protruding from a distal end of a longitudinal housing for introducing current to said electrode for cauterizing or cutting body tissue, the elastomeric seal comprising:

an elongated body portion contoured for fitting upon said electrosurgical device, said elongated body portion further defining a first opening at a distal end and a second opening at a proximal end for fitting the elastomeric seal over the housing of said electrosurgical device; and

a lip portion circumferentially surrounding said first opening.

30. An electrosurgical device comprising:

a longitudinal housing having a switching mechanism disposed thereon, an actuator area, and a nose area configured for inserting an electrode therein, said housing further having circuitry therein electrically coupled to said switching mechanism;

an electrical cord electrically coupled to said circuitry and extending from a proximal end of said housing;

a plug connector having a counting mechanism, the plug connector connected to a proximal end of said electrical cord and configured for connecting to a power supply source for supplying current to said circuitry via said electrical cord, said counting mechanism having structure for counting the number of times said plug connector is coupled to said power supply source;

an elastomeric seal formed integral with said housing having a lip portion circumferentially extending from said nose area; and

an actuator elastomeric seal disposed around said actuator area and operatively associated with said switching mechanism.

31. The electrosurgical device of claim 30, wherein said switching mechanism includes at least one moving contact having a moving contact face aligned with a stationary contact face of a stationary contact, wherein said moving contact face slides along said stationary contact face when said actuator seal is actuated to clean said moving and stationary contact faces.

32. A kit for performing electrosurgical procedures comprising:

an electrosurgical device having a longitudinal housing;

at least one elastomeric seal formed integral with said housing for sealing components therein; and

a plug connector having a counting mechanism, the plug connector connected to a proximal end of an electrical cord, said electrical cord configured for coupling said counting mechanism with circuitry within said housing of said electrosurgical device, said counting mechanism configured for connecting to a power supply source for supplying current to said circuitry via said electrical cord, said counting mechanism having structure for counting the number of times said plug connector is coupled to said power supply source.

33. The kit according to claim 32, wherein said electrosurgical device comprises a switching mechanism including at least one moving contact having a moving contact face aligned with a stationary contact face of a stationary contact, wherein said moving contact face slides along said stationary contact face when said switching mechanism is actuated to clean said moving and stationary contact faces.