Anti-microbial electrosurgical electrode and method of manufacturing same

• US 7,718,212 B2
• Filed: 10/26/2007
• Issued: 05/18/2010
• Est. Priority Date: 12/12/2002
• Status: Active Grant

• Current Assignee: Innovatech, LLC
• Original Assignee: Innovatech, LLC
• Inventors: Nesbitt, Bruce
• Primary Examiner(s): Parker; Frederick J
• Assistant Examiner(s): Sellman; Cachet I
• Application Number:
  US11/925,341
• Publication Number:
  US 20080050509A1
• Time in Patent Office: 935 Days
• Field of Search: 427 21- 231, 427/458, 427/470, 427/475, 606 45- 48
• US Class Current: 427/2.1
• CPC Class Codes: A47J 36/025 Vessels with non-stick features, e.g. coatings
• CPC Class Codes: A61B 18/14 Probes or electrodes therefor
• CPC Class Codes: A61B 18/1402 Probes for open surgery
• CPC Class Codes: A61B 2018/0013 non-sticking
• CPC Class Codes: A61B 2018/00148 with metal
• CPC Class Codes: A61L 2300/104 Silver, e.g. silver sulfadiazine
• CPC Class Codes: A61L 2300/404 Biocides, antimicrobial agents, antiseptic agents
• CPC Class Codes: A61L 2420/02 Methods for coating medical devices
• CPC Class Codes: A61L 2420/08 Coatings comprising two or more layers
• CPC Class Codes: A61L 31/10 Macromolecular materials
• CPC Class Codes: A61L 31/16 Biologically active materials, e.g. therapeutic substances A61L31/047 takes precedence
• CPC Class Codes: B05D 2601/20 used for non-pigmentation effect
• CPC Class Codes: B05D 3/0281 with induction heating
• CPC Class Codes: B05D 3/20 by magnetic fields
• CPC Class Codes: B05D 5/00 Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
• CPC Class Codes: B05D 5/02 to obtain a matt or rough surface
• CPC Class Codes: B05D 5/06 to obtain multicolour or other optical effects B05D5/02 takes precedence
• CPC Class Codes: B05D 5/08 to obtain an anti-friction or anti-adhesive surface rendering particulate materials free-flowing in general, e.g. making them hydrophobic B01J2/30
• CPC Class Codes: B05D 5/083 involving the use of fluoropolymers
• CPC Class Codes: B05D 7/52 Two layers
• CPC Class Codes: B05D 7/54 : No clear coat specified
• CPC Class Codes: B65G 2249/02 : Controlled or contamination-free environments or clean space conditions
• CPC Class Codes: B65G 49/064 : in a horizontal position B65G49/066 takes precedence
• CPC Class Codes: C03B 35/14 : Transporting hot glass sheets or ribbons, e.g. by heat-resistant conveyor belts or bands
• CPC Class Codes: F16C 33/201 : Composition of the plastic
• CPC Class Codes: Y10T 428/24372 : Particulate matter
• CPC Class Codes: Y10T 428/2438 : Coated
• CPC Class Codes: Y10T 428/24413 : Metal or metal compound
• CPC Class Codes: Y10T 428/254 : Polymeric or resinous material
• CPC Class Codes: Y10T 428/31725 : Of polyamide
• CPC Class Codes: Y10T 428/32 : Composite [nonstructural laminate] of inorganic material having metal-compound-containing layer and having defined magnetic layer

Abstract

An electrosurgical device including a reinforcing underlayment having a non-stick, anti-microbial coating. In one embodiment, the coating includes a non-stick material having anti-microbial particles interspersed in the non-stick material. This coating is applied to the surfaces of the electrode to minimize the build-up of charred tissue on the surfaces of the electrode. Also, the coating tends to kill harmful organisms residing on the surfaces of the electrode. In another embodiment, a primer coating is initially applied to the surfaces of the electrode. A plurality of anti-microbial particles are then applied to the primer coating layer and engage and are embedded in the primer coating layer. A top coat including a non-stick material is applied to the anti-microbial particle layer. In either embodiment, the coating layers applied to the surfaces of the electrode are cured to harden and adhere the layers to the electrode.

Claims

1. A method of coating a medical device including a metal substrate, said method comprising:

(a) applying a substantially uniform coating to a surface of the metal substrate of the medical device, said coating including a wet base material having a plurality of anti-microbial powder particles interspersed in said base material, said anti-microbial powder particles being at least partially electrostatically attached to the base material and being formulated to kill a microbial organism independent of any energy source; and

(b) at least partially curing said coating including the base material and the anti-microbial powder particles interspersed in the base material.

2. The method of claim 1, wherein the substrate is part of a surgical device.

3. The method of claim 1, which includes repeating (a) to (b) until a desired thickness is achieved.

4. The method of claim 1, wherein the anti-microbial powder particles include at least one of the group consisting of:

silver particles, ceramic particles and a combination of silver and ceramic particles.

5. The method of claim 1, wherein the wet bonding material includes a primer.

6. The method of claim 1, wherein the base material includes a non-stick material.

7. The method of claim 1, wherein the non-stick material includes at least one of the non-stick materials selected from the group consisting of:

a silicone, a polytetrafluoroethylene, a fluoropolymer, a ceramic and a combination of fluorosilicones.

8. The method of claim 1, which includes a plurality of different sized anti-microbial powder particles.

9. A method of forming a non-stick, wear-resistance coating on a surface of a substrate, said method comprising:

(a) applying an electrically or electrostatically grounded non-stick wet bonding material to the surface of the substrate;

(b) coating the bonding material with a layer of substantially uniform dry particles, wherein the dry particles have an electrical or electrostatic charge opposite the electrical charge of the bonding material; and

(c) shrinking the wet bonding material by at least partially curing the wet bonding material and the substantially uniform dry particles such that a plurality of the dry particles are substantially submerged within the cured bonding material and at least part of said dry particles protrude from the cured bonding material.

10. The method of claim 9, which includes applying a topcoating to the bonding material and dry particles.