Valleylab, Inc.

Sherwood Services Ag

Michael D Lontine

Gene H Arts

William Wayne Cimino

Jan E Carr

Michael P Schollmeyer

Karen T Kuk-Nagle

Brian A Millberg

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.

Partially coated electrodes, manufacture and use

A method of mass manufacturing a plurality of electrodes coated with a non-stick layer is disclosed for reducing eschar buildup and the like on the working tip of an electrode during electrosurgical procedures and facilitating ease of cleaning the tip. The plurality of electrodes are mass manufactured for connection to an appropriate electrical power source. One preferred method of mass manufacturing a plurality of electrodes includes the steps of: simultaneously coating at least a portion of a stock material with a non-stick layer; and forming the plurality of electrode blanks having the non-stick layer. The plurality of electrode blanks may be subjected to further finishing. Preferably, the plurality of electrode blanks are formed having the non-stick layer as the material is advanced through a stamping operation. Also, the material may be configured and dimensioned in the form of a tree to provide a plurality of electrode blanks with a non-stick layer.

Method of mass manufacturing coated electrosurgical electrodes

Partially coated electrodes

A design and method of manufacture is disclosed for an electrosurgical electrode with a silicone coating. The coating resists the buildup of eschar. The silicone material is thick enough in the flat area of the blade to withstand the electrosurgical voltage without breakdown. The electrosurgical current path is primarily through the blade edges and tip. The flat of the blade remains insulated under most conditions. The relatively thick coating also provides high tear strength and added durability. The composition of the electrode coatings may include silicone elastomers in the form of adhesives, dispersions, or liquid rubbers. The coating composition may also contain adhesion promoters, heat stabilizers, plasticizers, release enhancers, crosslinking agents, and colorants. Several methods of manufacture are illustrated by way of examples.

Coated electrosurgical electrode

An electrosurgical tip 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 has a metallic electrically and thermally conductive electrode for connection to an electrosurgical generator proximally and for transmission of the electromagnetic electrosurgical energy to the tissue and the bodily fluids of the animal or human distally. A sheath of heat shrinkable fluorinated polymeric substance is an electrical and thermal insulator held about the electrode for preventing the flow of electromagnetic and thermal energy from the metallic electrically and thermally conductive electrode to the tissue and the bodily fluids. A smooth surface of the sheath contacts the tissue and the bodily fluids and has a low surface free energy. Openings through the sheath extend from the electrode to the surface for permitting the passage of energy. A wall of the sheath is of a thickness adequate to space the electrode from substantially any contact with the tissue and isolate heat due to the arcs. A ceramic substance is an electrical and thermal insulator about the conductive electrode for preventing the energy flow. A method of making the tip includes covering the electrode with the insulator, isolating physically the heat generated due to the passage of energy. A method of using the tip places the surface in close proximity to the tissue and the bodily fluids, transmits the electromagnetic energy through the openings, allows cleaning tissue and bodily fluids from the surface. The use includes first passing energy through openings in a wall of electrical and thermal insulation and application of electromagnetic energy by either a monopolar or a bipolar circuit relative to the tissue and the bodily fluids of an animal or human.

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Westminster, CO, United States of America

Michael D Lontine