Multielectrode electrosurgical instrument

• US 8,357,154 B2
• Filed: 06/29/2006
• Issued: 01/22/2013
• Est. Priority Date: 07/20/2004
• Status: Active Grant

• Current Assignee: Microline Surgical, Inc. (Hoya Corporation)
• Original Assignee: Microline Surgical, Inc. (Hoya Corporation)
• Inventors: Heim, Warren P., Brassell, James L.
• Primary Examiner(s): Peffley, Michael
• Assistant Examiner(s): Good, Samantha
• Application Number:
  US11/427,643
• Publication Number:
  US 20060241587A1
• Time in Patent Office: 2,399 Days
• Field of Search: 606/41, 606/45, 606/50, 606/48
• US Class Current: 606/45
• CPC Class Codes: A61B 18/1402 Probes for open surgery
• CPC Class Codes: A61B 2017/00734 battery operated
• CPC Class Codes: A61B 2018/0013 non-sticking
• CPC Class Codes: A61B 2018/1412 Blade

Abstract

An improved electrosurgical instrument includes a body having more than two electrodes with at least two electrodes having alternating current power supplied to them provide a bipolar alternating current configuration and employ a means other than electrode spacing for reducing or preventing accumulation of eschar. The electrodes are separated from each other using electrically insulating materials such that electric current does not flow between at least two of the bipolar alternating current electrodes unless they contact at least one other electrically conductive medium, such as patient tissue. The conductor edge portion and insulation layer each have geometric shapes and composition to reduce or eliminate the production of smoke and eschar and reduce tissue damage. The outer profile of the insulation layer and conductive element are configured to facilitate the flow of electrosurgical decomposition products away from the conductor edge where they are formed.

Claims

1. An electrosurgical instrument for conveying electrosurgical power to tissue to achieve a predetermined electrosurgical effect, comprising:

an active electrode having a first section and a first tapered section terminating at a first conductor edge;

a first outermost insulation layer having a second tapered section generally following the contours of and overlaying the active electrode which tapers against a side of the first tapered section to expose the first conductor edge;

a return electrode electrically isolated from the active electrode, the return electrode having a third section and a third tapered section terminating at a second conductor edge; and

a second outermost insulation layer having a fourth tapered section generally following the contours of and overlaying the return electrode which tapers against a side of the third tapered section to expose the second conductor edge; and

a passive electrode electrically isolated from the active electrode and the return electrode.

2. The electrosurgical instrument as recited in claim 1, wherein at least a portion of the thickness of the first conductor edge is less than that of the first section.

3. The electrosurgical instrument as recited in claim 2, wherein the ratio of width of a first section to at least a portion of the first conductor edge is at least 5:

1.

4. The electrosurgical instrument as recited in claim 2, wherein the ratio of width of a first section to at least a portion of the first conductor edge is 20:

1.

5. The electrosurgical instrument as recited in claim 2, wherein at least a portion of the first conductor edge is flush against the first outermost insulation layer near the first conductor edge.

6. The electrosurgical instrument as recited in claim 5, wherein at least a portion of the first tapered section includes a beveled surface.

7. The electrosurgical instrument as recited in claim 6, wherein at least a portion of the first tapered section includes two beveled surfaces.

8. The electrosurgical instrument as recited in claim 7, wherein at least a portion of the first tapered section has a concave shape.

9. The electrosurgical instrument as recited in claim 8, wherein at least a portion of the second tapered section of the first outermost insulation layer has a linear taper shape.

10. The electrosurgical instrument as recited in claim 8, wherein at least a portion of the second tapered section has a concave shape.

11. The electrosurgical instrument as recited in claim 10, wherein at least a portion of the third tapered section has a concave shape.

12. The electrosurgical instrument as recited in claim 11, wherein at least a portion of the fourth tapered section has a concave shape.

13. The electrosurgical instrument as recited in claim 11, wherein at least a portion of the fourth tapered section has a linear taper shape.

14. The electrosurgical instrument as recited in claim 5, wherein at least one side of the first tapered section extends radially inward.

15. The electrosurgical instrument as recited in claim 14, wherein at least one side of the third tapered section extends radially inward.

16. The electrosurgical instrument as recited in claim 15, wherein a tangent to the insulation of at least one of the first and second outermost insulation layers at a respective at least one of the first conductor edge and second conductor edge forms an angle with a centerline of the instrument of less than about 45 degrees.

17. The electrosurgical instrument as recited in claim 15, wherein a tangent to the insulation of at least one of the first and second outermost insulation layers at a respective at least one of the first conductor edge and second conductor edge forms an angle with a centerline of the instrument of less than about 20 degrees.

18. The electrosurgical instrument as recited in claim 1, wherein a tangent to the insulation of at least one of the first and second outermost insulation layers at a respective at least one of the first conductor edge and second conductor edge forms an angle with a centerline of the instrument of less than about 60 degrees.

19. The electrosurgical instrument as recited in claim 1, wherein a tangent to the insulation of at least one of the first and second outermost insulation layers at a respective at least one of the first conductor edge and second conductor edge forms an angle with a centerline of the instrument of less than about 45 degrees.

20. The electrosurgical instrument as recited in claim 1, wherein a tangent to the insulation of at least one of the first and second outermost insulation layers at a respective at least one of the first conductor edge and second conductor edge forms an angle with a centerline of the instrument of less than about 20 degrees.

21. The electrosurgical instrument as recited in claim 1, wherein each of the first and second conductor edges has a thermal conductivity of at least 0.0002 W/°

K at about 300°

K.

22. The electrosurgical instrument as recited in claim 1, wherein at least a portion of the first conductor edge has a transverse cross section that comes to approximately a point.

23. The electrosurgical instrument as recited in claim 22, wherein at least a portion of the second conductor edge has a transverse cross section that comes to approximately a point.

24. The electrosurgical instrument as recited in claim 1, wherein at least a portion of the first conductor edge has a transverse cross section that forms an acute angle.

25. The electrosurgical instrument as recited in claim 24, wherein at least a portion of the second conductor edge has a transverse cross section that forms an acute angle.

26. The electrosurgical instrument as recited in claim 1, wherein at least a portion of the first conductor edge has a thickness less than about 0.005 inches.

27. The electrosurgical instrument as recited in claim 1, wherein at least a portion of the first conductor edge has a thickness less than about 0.002 inches.

28. The electrosurgical instrument as recited in claim 1, wherein at least a portion of the first conductor edge has a thickness less than about 0.0005 inches.

29. The electrosurgical instrument as recited in claim 1, wherein at least a portion of the thickness of the insulation layer within a primary reaction region is at least one half the thickness of either the first or second conductor edge.

30. The electrosurgical instrument as recited in claim 1, wherein the thickness of the first insulation layer a primary reaction region is at least as thick as the first conductor edge.

31. The electrosurgical instrument as recited in claim 1, further comprising a holder electrically and mechanically coupled as a unit to the active electrode and the return electrode, the holder comprising:

a connector for electrically connecting the holder to a source of radio frequency power; and

an electrical connector configured to electrically couple the active electrode and return electrode to radio frequency power and a negative voltage source and couple the passive electrode to a positive voltage source.

32. The electrosurgical instrument as recited in claim 1, further comprising a connector for electrically connecting the holder to the source of radio frequency power.

33. The electrosurgical instrument as recited in claim 31, further comprising a rectifier circuit configured to receive the radio frequency power and provide the source of negative and positive voltage.

34. The electrosurgical instrument as recited in claim 33, wherein the rectifier circuit is positioned within the holder.

35. The electrosurgical instrument as recited in claim 33, further comprising a radio frequency generator configured to provide the source of radio frequency power.

36. The electrosurgical instrument according to claim 1, wherein the passive electrode is electrically isolated from the active electrode and the return electrode by an inner insulation layer.

37. The electrosurgical instrument according to claim 1, wherein the passive electrode extends along a centerline of the instrument.

38. The electrosurgical instrument according to claim 1, wherein the first tapered section, second tapered section, third tapered section and fourth tapered section converge to form an instrument edge.

39. An electrosurgical instrument for conveying electrosurgical power to tissue to achieve a predetermined electrosurgical effect comprising:

an electrosurgical blade, the electrosurgical blade comprising;

an active electrode having a first section and a first tapered section terminating at a first conductor edge;

a first outermost insulation layer having a second tapered section generally following the contours of and overlaying the active electrode which tapers against a side of the first tapered section to expose the first conductor edge;

a return electrode electrically isolate from the active electrode, the return electrode having a third section and a third tapered section terminating at a second conductor edge;

a second outermost insulation layer having a fourth tapered section generally following the contours of and overlaying the return electrode which tapers against a side of the third tapered section to expose the second conductor edge; and

a passive electrode electrically isolated from the active electrode and the return electrode; and

a handle coupled to the electrosurgical blade.

40. The electrosurgical instrument as recited in claim 39, further comprising an electrical couple unit which couples the electrosurgical instrument to a radio frequency power source.

41. The electrosurgical instrument as recited in claim 40, wherein the electrical couple unit selectively releases the electrosurgical instrument.

42. The electrosurgical instrument as recited in claim 39, wherein the handle houses a coupling mechanism to securely and electrically couple the electrosurgical instrument to the handle.

43. The electrosurgical instrument as recited in claim 42, further wherein the coupling mechanism also couples the active electrode and the return electrode to a radio frequency power source and to a negative voltage source independent of the radio frequency power source, and couples the passive electrode to a positive voltage source independent of the radio frequency power source.

44. The electrosurgical instrument as recited in claim 39, further comprising a radio frequency (RF) power source electrically coupled to the active electrode and the return electrode;

and a DC voltage source providing a negative voltage coupled to the active electrode and the return electrode and a positive voltage coupled to the passive electrode.

45. The electrosurgical instrument as recited in claim 44, wherein the DC voltage source comprises a rectifier circuit configured to receive RF power from the RF power source and output the negative voltage and the positive voltage.

46. The electrosurgical instrument as recited in claim 45, wherein the rectifier circuit is positioned within the handle.

47. The electrosurgical instrument according to claim 39, wherein the passive electrode is electrically isolated from the active electrode and the return electrode by an inner insulation layer.

48. The electrosurgical instrument according to claim 39, wherein the passive electrode extends along a centerline of the instrument.

49. The electrosurgical instrument according to claim 39, wherein the first tapered section, second tapered section, third tapered section and fourth tapered section converge to form an instrument edge.

50. A sterile package kit for use in performing an electrosurgical procedure, comprising:

a sterile package; and

an electrosurgical instrument sealed within the sterile package, the electrosurgical instrument comprising;

an active electrode having a first section and a first tapered section terminating at a first conductor edge;

a first outermost insulation layer having a second tapered section generally following the contours of and overlaying the active electrode which tapers against a side of the first tapered section to expose the first conductor edge;

a return electrode electrically isolate from the active electrode, the return electrode having a third section and a third tapered section terminating at a second conductor edge;

a second outermost insulation layer having a fourth tapered section generally following the contours of and overlaying the return electrode which tapers against a side of the third tapered section to expose the second conductor edge;

a passive electrode electrically isolated from the active electrode and the return electrode; and

a handle sealed within the sterile package and electrically coupled to the active, return and passive electrodes.

51. The sterile package kit according to claim 50, further comprising an electrical connector coupled to the handle and configured to electrically couple the electrosurgical instrument to a radio frequency (RF) power source.

52. The sterile package kit according to claim 50, further comprising a rectifier circuit configured to receive RF power and output a negative and a positive DC voltage.

53. The sterile package kit according to claim 52, wherein the rectifier circuit is positioned within the handle and the handle is configured to provide the negative DC voltage to the active and return electrodes and positive DC voltage to the passive electrode.

54. The sterile package kit according to claim 50, further comprising printed instructions informing a user how to couple the electrosurgical instrument to the RF power source.

55. The sterile package kit according to claim 50, wherein the passive electrode is electrically isolated from the active electrode and the return electrode by an inner insulation layer.

56. The sterile package kit according to claim 50, wherein the passive electrode extends along a centerline of the instrument.

57. The sterile package kit according to claim 50, wherein the first tapered section, second tapered section, third tapered section and fourth tapered section converge to form an instrument edge.