Electrosurgical electrode and method of manufacturing same

• US 9,630,206 B2
• Filed: 07/28/2014
• Issued: 04/25/2017
• 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:
  US14/444,603
• Publication Number:
  US 20140336642A1
• Time in Patent Office: 1,002 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 which includes a solvent-free hydroxyl functional solid phenyl silicone resin in the range of about 40% to about 60% parts per weight of the coating; a calcium metasilicate in the range of about 20% to about 40% parts per weight of the coating; an epoxy cresol novalac resin in the range of about 5% to about 15% parts per weight of the coating; an ultra-fine air micronized muscovite mica in the range of about 0% to about 10% parts per weight of the coating; a 60% active powder version of a methyl alkyl polysilaxane in the range of about 3% to about 7% parts per weight of the coating; a high temperature calcination of coprecipitated compound with manganese-copper-iron in the range of about 0% to about 10% parts per weight of the coating; an o-cresol novolac resin in the range of about 0.5% to about 3% parts per weight of the coating; and an acrylate copolymer in the range of about 0.5% to about 3% parts per weight of the 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 powder coating applied to a first portion of the surface of the substrate, wherein the powder coating includes a plurality of powder particles each having a size of no greater than one-hundred-fifty microns and the powder coating at least includes;

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

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

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

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

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

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

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

3. The electrosurgical electrode of claim 2, wherein the metal includes stainless steel.

4. The electrosurgical electrode of claim 1, which includes an electrically insulative material applied to at least a second portion of the surface of the conductive substrate.

5. The electrosurgical electrode of claim 4, wherein the second portion of the surface of the conductive substrate underneath the electrically insulative material includes the powder coating.

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

7. The electrosurgical electrode of claim 6, wherein the anti-microbial particles include silver particles.

8. The electrosurgical electrode of claim 6, wherein the anti-microbial particles include ceramic particles.

9. The electrosurgical electrode of claim 1, which includes a single substantially uniform layer of the powder particles applied to the first portion of the surface of the substrate.

10. The electrosurgical electrode of claim 1, wherein a plurality of electrically conductive particles are interspersed in said powder coating.

11. The electrosurgical electrode of claim 1, wherein the plurality of powder particles include a plurality of different sized powder particles.

12. The electrosurgical electrode of claim 1, which includes a top coat applied to the powder coating, said top coat selected from the group consisting of:

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

13. 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 and a ball.

14. The electrosurgical electrode of claim 1, wherein the powder coating includes an ultra-fine air micronized muscovite mica in the range of about 0% to about 10% parts per weight of the powder coating.

15. The electrosurgical electrode of claim 1, wherein the powder coating includes a high temperature calcination of coprecipitated compound with manganese-copper-iron in the range of about 0% to about 10% parts per weight of the powder coating.

16. The electrosurgical electrode of claim 1, wherein the powder coating includes an aluminum pigment in the range of about 0% to about 6% parts per weight of the powder coating.

17. The electrosurgical electrode of claim 1, wherein the powder coating includes an ultra marine blue pigment in the range of about 0% to about 10% parts per weight of the powder coating.

18. A method of coating an electrosurgical electrode including a conductive substrate, said method comprising:

(a) applying a powder coating to at least a first portion of a surface of the conductive substrate, the powder coating including a plurality of powder particles each having a size of no greater than one-hundred-fifty microns and the powder coating at least including;

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

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

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

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

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

(f) an acrylate copolymer in the range of about 0.5% to about 3% parts per weight of the powder coating; and

(b) at least partially curing the applied powder coating.

19. The method of claim 18, wherein the powder coating includes a plurality of anti-microbial particles.

20. The method of claim 19, wherein the anti-microbial particles include silver particles.

21. The method of claim 19, wherein the anti-microbial particles include ceramic particles.

22. The method of claim 18, which includes applying an electrically insulative material to at least a second portion of the surface of the conductive substrate.

23. The method of claim 22, which includes applying the powder coating to the second portion of the surface of the conductive substrate underneath the insulative material.

24. The method of claim 18, wherein applying the powder coating to the first portion of the surface of the conductive substrate includes:

(i) grounding the first portion of the surface of the conductive substrate before applying the powder coating to the first portion of the surface of the conductive substrate,

(ii) charging the plurality of powder particles of the powder coating before applying the powder coating to the first portion of the surface of the conductive substrate, and

(iii) electrostatically applying the charged powder particles to the first portion of the surface of the conductive substrate.

25. The method of claim 18, wherein the powder coating includes a plurality of electrically conductive particles interspersed in said powder coating.

26. The method of claim 18, which includes applying a top coat to the at least partially cured applied powder coating.

27. The method of claim 26, wherein the 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.

28. The method of claim 18, wherein the powder coating includes an ultra-fine air micronized muscovite mica in the range of about 0% to about 10% parts per weight of the powder coating.

29. The method of claim 18, wherein the powder coating includes a high temperature calcination of coprecipitated compound with manganese-copper-iron in the range of about 0% to about 10% parts per weight of the powder coating.

30. The method of claim 18, wherein the powder coating includes an aluminum pigment in the range of about 0% to about 6% parts per weight of the powder coating.

31. The method of claim 18, wherein the powder coating includes an ultra marine blue in the range of about 0% to about 10% parts per weight of the powder coating.