Electrosurgical instrument

• US 7,935,112 B2
• Filed: 06/29/2006
• Issued: 05/03/2011
• Est. Priority Date: 06/30/2005
• 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:
  US11/427,607
• Publication Number:
  US 20070005054A1
• Time in Patent Office: 1,769 Days
• Field of Search: 606/41, 606/45
• US Class Current: 606/45
• CPC Class Codes: A61B 18/1402 Probes for open surgery
• CPC Class Codes: A61B 2018/00083 low, i.e. electrically insulating

Abstract

An electrosurgical instrument is disclosed for simplifying making incisions and other treatments using electrosurgery. The electrosurgical instrument comprises a body having at least one conductive element that is surrounded by an insulation layer except at a conductor edge portion of the conductive element. The conductor edge portion and insulation layer each having unique geometric shapes and composition of the parts 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 electrically conductive blade having a first section and a first tapered section terminating at a conductor edge; and

an insulation layer having a second tapered section overlaying the entire electrically conductive blade which tapers against a side of the first tapered section to expose the conductor edge at a distalmost end of the electrically conductive blade, forming a primary reaction region, wherein the conductor edge at the distalmost end of the electrically conductive blade is flush against the insulation layer.

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

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

1.

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

1.

5. The electrosurgical instrument as recited in claim 1, wherein the first tapered section includes at least one beveled surface.

6. The electrosurgical instrument as recited in claim 5, wherein the first tapered section includes two beveled surfaces.

7. The electrosurgical instrument as recited in claim 6, wherein at least a portion of the first tapered section has a concave shape.

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

9. The electrosurgical instrument as recited in claim 7, wherein at least a portion of the second tapered section insulation layer has a linear taper shape.

10. The electrosurgical instrument as recited in claim 7, wherein at least a portion of each side of the second tapered section insulation layer has a convex shape.

11. The electrosurgical instrument as recited in claim 1, wherein a tangent to the insulation layer at the conductor edge forms an angle with a centerline of the electrically conductive blade of less than about 60 degrees.

12. The electrosurgical instrument as recited in claim 11, wherein the conductor edge has a thermal conductivity characteristic of at least 0.0002 W/°

K at about 300°

K.

13. The electrosurgical instrument as recited in claim 1, wherein a tangent to the insulation layer at the conductor edge forms an angle with a centerline of the electrically conductive blade of than about 45 degrees.

14. The electrosurgical instrument as recited in claim 1, wherein a tangent to the insulation layer at the conductor edge forms an angle with a centerline of the electrically conductive blade of less than about 20 degrees.

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

16. The electrosurgical instrument as recited in claim 1, wherein the conductor edge has a cross section that forms an acute angle.

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

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

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

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

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

22. The electrosurgical instrument as recited in claim 1, wherein at least a portion of each side of the first tapered section extends radially inward and proximately intersects with one another at the conductor edge.

23. The electrosurgical instrument as recited in claim 22, wherein at least a portion of each side of the second tapered section extends radially inward and proximately intersects with one another at the conductor edge.

24. The electrosurgical instrument as recited in claim 1, wherein at least a portion of each side of the first tapered section extends linearly inward and proximately intersect with one another at the conductor edge.

25. The electrosurgical instrument as recited in claim 24, wherein at least a portion of each side of the second tapered section extends linearly inward and proximately intersect with one another at the conductor edge.

26. The electrosurgical instrument as recited in claim 24, wherein at least a portion of each side of the second tapered section extends radially outward and proximately intersect with one another at the conductor edge.

27. The electrosurgical instrument as recited in claim 26, wherein a tangent to the insulation layer at the conductor edge forms an angle with a centerline of the blade of less than about 45 degrees.

28. The electrosurgical instrument as recited in claim 26, wherein a tangent to the insulation layer at the conductor edge forms an angle with a centerline of the blade of less than about 20 degrees.

29. The electrosurgical instrument as recited in claim 1, further comprising:

a holder electrically and mechanically coupled to the electrically conductive blade as a unit.

30. The electrosurgical instrument as recited in claim 29, further comprising a connector for electrically connecting the holder to a source of radio frequency power.

31. The electrosurgical instrument as recited in claim 29, further comprising a cable electrically coupled to the holder and configured for electrically connecting the holder to a source of radio frequency power.

32. The electrosurgical instrument as recited in claim 1, wherein the conductor edge is flush against the insulation layer to form a singular convex tapered section at the distalmost end of the electrically conductive blade.

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

an electrosurgical blade, the electrosurgical blade comprising;

an electrically conductive blade having a first section and a first tapered section which tapers to a conductor edge; and

an insulation layer having a second tapered section overlaying the entire electrically conductive blade which tapers against the conductor edge to expose the conductor edge at a distalmost end of the electrically conductive blade, wherein the conductor edge at the distalmost end of the electrically conductive blade is flush against the insulation layer; and

a handle coupled to the electrosurgical blade.

34. The electrosurgical instrument as recited in claim 33, further comprising an electrical couple unit which couples the electrosurgical instrument to a radio frequency power source.

35. The electrosurgical instrument as recited in claim 33, wherein the handle houses a coupling mechanism to couple securely to the electrosurgical instrument to the handle.

36. The electrosurgical instrument as recited in claim 35, further wherein the coupling mechanism also couples the electrosurgical instrument to a radio frequency power source.

37. The electrosurgical instrument as recited in claim 35, further wherein the coupling mechanism selectively releases the electrosurgical instrument.

38. The electrosurgical instrument as recited in claim 33, further comprising a radio frequency power source electrically coupled to the electrically conductive blade.

39. The electrosurgical instrument as recited in claim 33, further comprising an electrical couple unit which selectively couples the electrosurgical instrument to a radio frequency power source.

40. The electrosurgical instrument as recited in claim 33, wherein the conductor edge is flush against the insulation layer to form a singular convex tapered section at the distalmost end of the electrically conductive blade.

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

a sterile package;

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

an electrically conductive blade having a first section and a first tapered section terminating at a conductor edge; and

an insulation layer having a second tapered section overlaying the entire electrically conductive blade which tapers against a side of the first tapered section to expose the conductor edge at a distalmost end of the electrically conductive blade, forming a primary reaction region, wherein the conductor edge at the distalmost end of the electrically conductive blade is flush against the insulation layer;

a handle sealed within the sterile package and coupled to the electrically conductive blade; and

an electrical connector coupled to the handle and configured to electrically couple the electrosurgical instrument to a radio frequency power source.

42. The sterile package kit according to claim 41, further comprising printed instructions informing a user how to securely couple the electrosurgical instrument to the radio frequency power source.

43. The sterile package kit according to claim 41, wherein the conductor edge is flush against the insulation layer to form a singular convex tapered section at the distalmost end of the electrically conductive blade.