Partially coated electrodes, manufacture and use

• US 6,139,547 A
• Filed: 08/22/1997
• Issued: 10/31/2000
• Est. Priority Date: 12/30/1994
• Status: Expired due to Term

• Current Assignee: Covidien AG (Medtronic Plc)
• Original Assignee: Sherwood Services AG
• Inventors: Arts, Gene, Lontine, Michael D.
• Primary Examiner(s): Dvorak, Linda C. M.
• Assistant Examiner(s): Ruddy, David M.
• Application Number:
  US08/934,688
• Time in Patent Office: 1,166 Days
• Field of Search: 606/41-50, 606/32, 606/35, 607/152
• US Class Current: 606/41
• CPC Class Codes: A61B 18/1402 Probes for open surgery
• 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 2018/0091 Handpieces of the surgical instrument or device
• CPC Class Codes: A61B 2018/1412 Blade
• CPC Class Codes: A61B 2018/1467 using more than two electrodes on a single probe

Abstract

A partially coated electrosurgical electrode has a portion of a medical grade metallic material as a substrate for energy application. Conductive of sites of metallic material or alloys thereof pass energy through peaks that define valleys nearby. A partial coating in the valleys has a low surface free energy. A treated surface across the peaks and generally over the filled valleys is relatively smooth for non stick characteristics during application of electrosurgery to tissue and bodily fluids. Openings in the treated surface through the partial coating are at the peaks of conductive sites to expose the metallic material or alloys thereof. The partial coating is a fluorinated polymer. The treated surface is a relatively even level that is not flat. The metallic material substrate is an alloy of stainless steel or nickel chrome. A mechanically deformed surface finish, plasma or vapor deposition on the substrate forms the conductive sites. A method of manufacturing the electrode has steps including preparing it the metallic conductor, making it with the conductive material having peaks above the valleys as conductive sites, applying the partial coating to it and treating the surface across the peaks and generally over the filled valleys of the partially coated electrically conductive electrode. Locating the openings among the valleys is a step. Treating may be mass finishing, such as vibratory or tumbling the partially coated electrodes with or without abrasive material media or polishing, buffing, surface grinding, abrasive belt grinding or sanding with abrasive material. Making the peaks and valleys can be by stamping, coining, burnishing, embossing, threading, tumbling, vibrating, shot peening, wire brushing, grit blasting, thermal spraying, with powder, with wire supplied to melt and be distributed, or with high velocity oxygen fuel and a nickel, cobalt alloy, stainless steel or a nickel chrome alloy. A manufacturing method for the electrode has coating a strip of metal with the low surface energy polymer and forming it in a stamping operation with a raw edge metal edge.

Claims

1. A partially coated electrosurgical electrode for the application of electromagnetic energy in either a monopolar or a bipolar circuit through the tissue and the bodily fluids of an animal or human comprising:

an electrically conductive electrode for connection to a source of electromagnetic electrosurgical energy and for transmission of the electromagnetic electrosurgical energy in the circuit to and through the tissue and the bodily fluids of the animal or human;

a portion of the electrically conductive electrode having a medical grade biocompatible metallic material as a substrate thereof, the portion located for the application of electromagnetic energy in either a monopolar or a bipolar circuit to and through the tissue and the bodily fluids of an animal or human;

conductive sites for passing electrosurgical energy, the conductive sites located on and in uninterrupted contact with the portion of the medical grade biocompatible metallic material substrate, the conductive sites including peaks and valleys and formed of conductive material, wherein the conductive sites on the substrate transmits energy in the form of electrons and wherein the medical grade biocompatible metallic material substrate is substantially an electric arc sprayed deposition of an alloy of stainless steel;

a partial coating residing primarily in the valleys disposed for contact with the tissue and the bodily fluids of the animal or human during electrosurgical application of the partially coated electrosurgical electrode, the partial coating having a low surface free energy, wherein the partial coating is a fluorinated polymer and includes a compounded solid lubricant;

a treated surface substantially across the peaks and generally over the filled valleys of the partially coated electrically conductive electrode, the treated surface being relatively smooth for non stick characteristics during application of electrosurgical effects to tissue and bodily fluids, and

openings in the treated surface through the partial coating, the openings formed in the treated surface at the peaks exposing the conductive material of the conductive sites, the openings located primarily among the valleys filled with the partial coating, wherein the treated surface is reduced to a level so the openings and the filled valleys of the partial coating form a generally smooth surface for reducing mechanical coupling of coagulum and lowering the surface free energy thereacross.

2. A partially coated electrosurgical electrode for the application of electromagnetic energy in an electrosurgical circuit, the partially coated electrode comprising:

an electrically conductive electrode adapted for connection to a source of electromagnetic electrosurgical energy and for transmission of the electromagnetic electrosurgical energy in the circuit;

a portion of the electrically conductive electrode having a medical grade biocompatible metallic material, the portion located for the application of electromagnetic energy in the circuit;

conductive sites for passing electrosurgical energy, the conductive sites located on and in uninterrupted contact with the portion of the medical grade biocompatible metallic material, the conductive sites formed of conductive material;

a partial polymer coating disposed on the conductive sites for use in electrosurgical application of the partially coated electrosurgical electrode, the partial coating having a low surface free energy, and

openings through the partial coating, the openings exposing the conductive sites, the openings and the partial polymer coating forming a generally undulating surface.

3. The partially coated electrosurgical electrode of claim 2 wherein the polymer coating is compounded with a solid lubricant.

4. The partially coated electrosurgical electrode of claim 3 wherein the solid lubricant is graphite.

5. The partially coated electrosurgical electrode of claim 3 wherein the solid lubricant is molybdenum disulfide.

6. A partially coated electrosurgical electrode for cutting and coagulating tissue, the electrode comprising:

a substrate;

a stratum disposed in uninterrupted contact with the substrate and in electrical communication therewith; and

a partial coating disposed on the stratum, the partial coating defining openings exposing the stratum.

7. A partially coated electrosurgical electrode according to claim 6, wherein the partial coating is a fluorinated polymer including a solid lubricant.

8. A partially coated electrosurgical electrode according to claim 6, further including a treated surface disposed on the partial coating.

9. A partially coated electrosurgical electrode according to claim 6, wherein the stratum includes a portion configured as peaks and valleys.