Overmolded electrocautery dissection device and system with gas delivery assembly

Abstract

An electrocautery device for dissecting biological tissue is provided. The electrocautery device includes an insulated electrode including a distal tip configured to provide energy to the biological tissue and an electrocautery device body having a lower portion and an upper portion. The lower portion is disposed radially over the insulated electrode. The upper portion includes a proximal first portion including a gas supply connection and a distal second portion defining a gas delivery channel and having a gas tip. The electrocautery device can optionally include a bumper. A system for dissecting biological tissue is also provided.

Description

[0001] Cross-referencing related applications

[0002] This application claims the benefit of U.S. Patent Application No. 18 / 644,578, filed April 24, 2024, and U.S. Provisional Patent Application No. 63 / 607,459, filed December 7, 2023, each of which is incorporated herein by reference in its entirety. Technical Field

[0003] This invention relates to electrocautery devices and systems for dissecting biological tissues. These devices and methods are generally applicable to medical settings, and more specifically to surgical settings. Background Technology

[0004] Electrocautery devices dissect, cut, coagulate, dry, and / or electrocauterize biological tissue by applying an electric current to the tissue via an electrocautery tip on the device. Electrocautery devices can be operated using a cauterization handpiece that, when connected to a power source (e.g., a generator), allows the user to selectively change the amount of power supplied from the power source to the electrocautery device, thereby facilitating controlled tissue dissection. Electrocautery devices currently known in the art are not reliably safe when used near fragile and vital structures such as blood vessels and nerves.

[0005] During surgical procedures, known cauterization tips can potentially damage blood vessels if they come into direct contact with or are too close to them during tissue cutting and dissection. Furthermore, the effectiveness of existing cauterization devices can be adversely affected by factors such as the accumulation of bodily fluids (e.g., blood) in the surgical area and the formation of char build-up on the cauterization tip. Moreover, known cauterization devices produce smoke, which can reduce visibility in the surgical environment and potentially cause fires in hyperoxic surgical areas such as the head, neck, and chest regions where oxygen is being delivered to the patient.

[0006] Therefore, there is a need for electric soldering devices and methods of use that can be used safely and effectively around fluids without causing tissue damage and reducing the risk of fire. Summary of the Invention

[0007] In a first aspect, an electrocautery device for dissecting biological tissue is provided. The electrocautery device includes an insulating electrode and an electrocautery device body. The insulating electrode includes an electrode and an insulating material, the electrode having a distal end configured to deliver current to the biological tissue and a proximal end configured to couple to an energy supply source, the insulating material being disposed radially only on the middle portion of the electrode such that the distal and proximal ends of the electrode are not covered by the insulating material. The electrocautery device body is formed of a device body material and includes a lower portion radially disposed on the insulating electrode and an upper portion formed as a single integral part with the lower portion. The upper portion defines a gas delivery assembly including a first portion formed at the proximal end of the upper portion and a second portion formed at the distal end of the upper portion and adjacent to the first portion. The first portion of the upper portion includes a gas supply connector configured to couple to a gas supply source. The second part defines a gas delivery channel with a gas end, wherein the gas delivery channel is in fluid communication with a gas supply connector, such that when a gas supply source is coupled to the gas supply connector, the gas delivery channel is configured to deliver gas supplied by the gas supply source to biological tissue via the gas end.

[0008] In some embodiments, the insulating electrode is formed by overmolding an insulating material onto the center of the electrode. In some such embodiments, the insulating material may be overmolded onto the center of the electrode by injection molding. In some embodiments, the soldering device body is formed by overmolding a device body material onto the insulating electrode. In some such embodiments, the insulating material may be overmolded onto the center of the electrode by injection molding. In some embodiments, the insulating material may be overmolded onto the center of the electrode by compression molding.

[0009] In some embodiments, the distal end of the electrode is shaped like a blade. In some embodiments, the gas end is formed of a third material different from the insulating material and the device body material. In some embodiments, the gas end is disposed adjacent to the distal end of the insulating electrode. The gas end may contact the distal end at at least one location to facilitate a preferred gas dispersion pattern.

[0010] In some embodiments, the gas supply connection is a threaded connection. Additionally or alternatively, the gas supply connection may be a tapered connection configured to facilitate a frictional engagement between the gas supply source and the gas supply connection.

[0011] In some embodiments, the insulating electrode further includes a buffer disposed on the outer surface of the insulating material and configured to mitigate or prevent deformation of the insulating material. In such embodiments, the buffer may optionally include one or more lugs at at least one end of the buffer, and the insulating material includes anti-rotation tabs. In such embodiments, the lugs and anti-rotation tabs are configured to interact such that the buffer is held in place by the anti-rotation tabs.

[0012] In some embodiments, the proximal end of the electrode is configured to be coupled to a handheld device operably coupled to an energy supply source and configured to increase or decrease the amount of power supplied to the soldering device by current when manipulated by a user.

[0013] In some embodiments, the second portion of the upper part of the soldering device body forms an acute angle with the lower part of the soldering device body. In some embodiments, the second portion of the upper part of the soldering device body and the lower part of the soldering device body are inclined such that the angle between its proximal end and the lower part of the device body is smaller than the angle between its distal end and the lower part of the device body. In other embodiments, the second portion of the upper part of the soldering device body and the lower part of the soldering device body are inclined such that the angle between its proximal end and the lower part of the device body is greater than the angle between its distal end and the lower part of the device body.

[0014] In a second aspect, a system for dissecting biological tissue is provided. The system includes an electrocautery apparatus, a gas supply source coupled to a gas supply element of the electrocautery apparatus via a gas supply tube, an energy supply source configured to supply current to the electrodes of the electrocautery apparatus, and a handheld component operatively coupled to the energy supply source. In some embodiments, the gas supply tube is permanently coupled to a gas supply connector of the electrocautery apparatus via an overmolded gas supply connector.

[0015] An electrocautery device for dissecting biological tissues includes an insulating electrode and an electrocautery device body. The insulating electrode comprises an electrode and an insulating material. The electrode has a distal end configured to deliver current to the biological tissue and a proximal end configured to couple to an energy supply source. The insulating material is disposed radially only on the middle portion of the electrode, such that the distal and proximal ends of the electrode are not covered by the insulating material. The electrocautery device body is formed of the device body material and includes a lower portion radially disposed on the insulating electrode and an upper portion formed as a single integral part with the lower portion. The upper portion defines a gas delivery assembly including a first portion formed at the proximal end of the upper portion and a second portion formed at the distal end of the upper portion and adjacent to the first portion. The first portion of the upper portion includes a gas supply connector configured to couple to a gas supply source. The second portion defines a gas delivery channel having a gas end, wherein the gas delivery channel is in fluid communication with the gas supply connector, such that when the gas supply source is coupled to the gas supply connector, the gas delivery channel is configured to deliver gas supplied by the gas supply source to the biological tissue via the gas end.

[0016] In some embodiments, the system further includes a gas pump operatively coupled to the proximal end of the gas tube and configured to facilitate gas movement from a gas source to a gas delivery assembly of the soldering device. In some such embodiments, the gas tube is secured to the wires of the handheld device via a coupler. Attached Figure Description

[0017] To understand and see how the present disclosure can be practiced, embodiments will now be described by way of non-limiting example only, with reference to the accompanying drawings, in which: Figure 1A The diagram illustrates the electrodes used in an electric soldering device.

[0018] Figure 1B The diagram illustrates an electrode with an insulating material layer disposed thereon.

[0019] Figure 1C The diagram shows Figure 1B Isometric view of the insulating electrode.

[0020] Figure 2 An example of an electric soldering device is illustrated.

[0021] Figure 3 The diagram shows Figure 2 Additional view of the soldering device.

[0022] Figure 4 The diagram shows Figure 2 Another additional view of the soldering device.

[0023] Figure 5 An example of an electric soldering device is illustrated, in which a section of insulating material is recessed to define a notch.

[0024] Figure 6 The illustration shows a buffer configured to be placed around an insulating material.

[0025] Figure 7A The diagram illustrates an insulating electrode having an insulating material shaped to define an anti-rotation tab for connection with a buffer.

[0026] Figure 7B The diagram illustrates the process of forming. Figure 7A The electrode with anti-rotation protrusion.

[0027] Figure 8 The illustration shows a soldering device with a buffer surrounding an insulating material.

[0028] Figure 9 An example of an electric soldering apparatus is illustrated, in which the distal end of the gas delivery assembly is formed of different materials.

[0029] Figure 10 An example of an electric soldering apparatus is illustrated, in which the distal end of the gas delivery assembly is tilted.

[0030] Figure 11 The illustration shows an example of a soldering device that also includes a gas supply pipe.

[0031] Figure 12An example of a soldering device with an extended length is illustrated.

[0032] Figure 13 An example of an electric soldering device with an extended length and a tilted distal end is illustrated.

[0033] Figure 14 An exemplary electrosurgical handheld device for use with an electrocautery device is illustrated.

[0034] Figure 15 An example of an electrocautery device coupled to an electrosurgical handpiece is illustrated.

[0035] Figure 16 An example of a system used for dissecting biological tissues is illustrated. Detailed Implementation

[0036] The invention will now be described more fully below with reference to the accompanying drawings, which illustrate some, but not all, embodiments of the invention. Indeed, the invention can be embodied in many different forms and should not be construed as limited to the embodiments set forth herein; rather, these embodiments are provided so that this disclosure will satisfy applicable legal requirements. Throughout the text, the same numerals refer to the same elements. As used in the specification and appended claims, the singular forms “a,” “an,” and “the” include plural designations unless the context clearly indicates otherwise.

[0037] definition

[0038] As used herein, the terms “coupled” and “operably coupled” can refer to one or more components being electrically, mechanically, thermally, chemically, or otherwise linked to one or more other components. For example, components may be part of the same structure and / or integral with each other (i.e., “directly coupled”). In other examples, components may be connected via remote means (e.g., via signals transmitted to electronic circuitry).

[0039] As used herein, the term “anatomy” (and all its derivatives) may refer to the dissection, cutting, drying and / or electrocautery of tissues, as well as the coagulation of biological fluids.

[0040] As used herein, the term “overmolding” (and all its derivatives) can refer to any process of molding material onto a substrate, such as by means of non-limiting examples: compression molding or injection molding.

[0041] The present invention is an electrocautery device including a low-profile gas delivery assembly configured to deliver gas while dissecting biological tissue, thereby reducing smoke generation and potential fire hazards by lowering the oxygen concentration in the surgical area, keeping the surgical area dry, removing debris, and increasing the visibility of the surgical site.

[0042] The electrocautery device is constructed by coating the middle of the electrode with an insulating material to form an insulated electrode. The distal end of the electrode remains exposed to contact tissue, and the proximal end of the electrode is exposed to attach to an electrosurgical handheld device. The insulated electrode is then encapsulated with the device body material to form the body of the electrocautery device. Optionally, a buffer may be added between the insulating material and the device body material to prevent deformation of the insulating material during the encapsulation process.

[0043] refer to Figure 1A The figure illustrates electrode 13. Electrode 13 includes a distal end 12 and a proximal end 11, the distal end 12 being configured to deliver an electric current to biological tissue, and the proximal end 11 being configured to couple to an energy source. The size and design of the proximal end 11 of electrode 13 allow it to be operatively coupled to electrosurgical handheld devices supplied by a variety of different manufacturers. In some embodiments, the distal end 12 is shaped in a manner conducive to cutting tissue, such as a blade shape. The length of electrode 13 can vary depending on the type of operation desired.

[0044] Electrode 13 is made of a conductive material such as a metal or metal alloy. In some embodiments, electrode 13 is made of stainless steel such as 304 stainless steel. To enhance self-cleaning capabilities, the distal end 12 may be coated with a polymer layer, such as a PTFE layer.

[0045] In some embodiments, electrode 13 may be and / or include a monopolar blade electrode, a bipolar electrode, and / or the like. Additionally or alternatively, electrode 13 may be and / or include multiple electrodes.

[0046] refer to Figure 1B and Figure 1C The diagram illustrates an electrode 13 having a layer of insulating material 14 radially disposed on the center of the electrode. The insulating material 14 is overmolded onto the electrode to form a body 15, which is cylindrical to prevent snagging. The proximal end of the insulating material 14 is formed in a hexagonal shape to facilitate coupling with an electrosurgical handpiece. The distal end 12 and proximal end 11 of the electrode are exposed (i.e., not covered by the insulating material).

[0047] Compared to the material of the device body and the materials constituting the electrodes, the insulating material can be selected from materials having a relatively low dielectric constant. In some embodiments, the insulating material includes a polymer. In some such embodiments, the insulating material includes PTFE.

[0048] In various embodiments, additional textures may be added to the insulators 16A and 16B to improve the adhesion between the insulating electrodes (e.g., formed by the electrodes 13 and the insulating material 14) and the insulating body 32 (shown in the figure) by improving the traction between the material forming the soldering device body and the insulating body. Figure 2 The texture also helps the user hold the cauterization device during tissue dissection.

[0049] refer to Figure 2-4 The figure shows an electric soldering apparatus 30. The electric soldering apparatus includes an insulating electrode 31 and an electric soldering apparatus body 32, the electric soldering apparatus body 32 having a lower portion 21 arranged radially around the insulating electrode 31 and an upper portion 33 formed as a single integral part with the lower portion.

[0050] The upper portion 33 of the soldering apparatus body includes a first portion 34 at its proximal end and a second portion 22 at its distal end. The first portion 34 includes a gas supply connector 37, which is coupled to a gas supply source. The gas supply source may be coupled directly or alternatively via a gas supply tube to the gas supply connector. In some embodiments, the gas supply connector includes threads 37A to accommodate a gas supply source that can be coupled via a threaded adapter of the gas supply connector. In some such embodiments (e.g.) Figure 3 (As depicted), the thread is located on the inner surface of the gas supply connector. Additionally or alternatively, the thread may be located on the outer surface of the gas supply connector. In some embodiments, the gas supply connector is tapered to form a frictional fit with the gas supply source, for example in a Luer taper.

[0051] In some embodiments, the soldering apparatus further includes a gas tube and / or a gas source. In such embodiments, the gas tube is permanently coupled to a gas supply connector of the soldering apparatus via overmolding. For example, one or more materials may be overmolded over at least a portion of the overlapping section of the gas tube and the gas supply connector. Alternatively, the gas tube may be permanently coupled to the soldering apparatus by overmolding the gas tube with the device body material defining the gas supply connector. This connection may be formed during the initial formation of the soldering apparatus body.

[0052] A second portion 22 is formed at the distal end of the upper portion and is adjacent to the first portion. The second portion defines a gas delivery channel having a gas tip 35 at its distal end. The gas tip is positioned tangentially to the flat side of the blade and behind the distal end of the blade to minimize the possibility of blockage. The gas delivery channel 36 is in fluid communication with a gas supply connector 37, allowing unobstructed flow of gas through the gas delivery channel and delivery to tissue adjacent to the distal end of the electrocautery device during use. The second portion 22 is angled at its distal end. In some embodiments, the second portion forms an acute angle relative to the distal end 12 and is positioned at a distance of 3 mm to 10 mm proximal to the distal end 12 of the electrocautery device, thereby providing additional stability to the gas tip. In some embodiments, the second portion is positioned approximately 3 mm from the distal end. In some embodiments, the second portion is positioned approximately 4 mm from the distal end. In some embodiments, the second portion is positioned approximately 5 mm from the distal end. In some embodiments, the second portion is positioned approximately 6 mm from the distal end. In some embodiments, the second portion is positioned approximately 7 mm from the distal end. In some embodiments, the second portion is disposed approximately 8 mm from the distal end. In some embodiments, the second portion is disposed approximately 9 mm from the distal end. In some embodiments, the second portion is disposed approximately 10 mm from the distal end.

[0053] In some embodiments, the second portion is at an angle between 5 and 45 degrees relative to the distal end 12. In some embodiments, the outer diameter of the gas end is less than or equal to the width of the distal end in order to provide concentrated gas delivery to the target structure.

[0054] In some embodiments, the gas terminator can be overmolded, for example, by compression molding. The gas terminator can be formed of a translucent material to facilitate visualization and reveal potential blockages.

[0055] The gas end 35 is positioned such that, when gas is delivered, it is dispersed linearly through the distal end 12 of the electrode and along adjacent tissues not intended for dissection. In some embodiments, the airflow is confined to one side of the gas end. This adjacent tissue typically includes fragile structures such as blood vessels and nerves, which are gently pushed away from the cauterization end of the electrocautery device while the cauterization end maintains firm contact with the tissue. Additionally, when the electrocautery device is used for coagulation, the gas can help remove excess blood from the surgical area while the blade edge opposite the gas end maintains firm contact with the bleeding site for coagulation, as there is no direct airflow that would inhibit contact. The gas keeps the surgical tissue relatively dry, increases surgical visibility, prevents eschar buildup on the blade, and reduces the risk of fire in the surgical area. Notably, in some embodiments, the gas delivery assembly is configured to deliver any fluid (i.e., gas and / or liquid).

[0056] The soldering device body can be formed by overlaying a molded device body material onto the insulating electrode 31. In some embodiments, the upper portion 33 and lower portion 32 of the soldering device body are molded as a single integral piece onto the insulating electrode 31. The soldering device body 32 is formed of a non-conductive material (e.g., plastic). In various embodiments, the soldering device body includes one or more materials having properties more favorable for gas delivery than the insulating material, such as relatively high tensile strength. In some embodiments, the device body material has a higher flexural modulus than the first insulating material because threaded connections made with a softer material, such as an insulating material, may allow excessive rotation of the threaded gas tube, leading to thread damage and unsafe gas connections on the assembly. In some embodiments, the device body material includes ABS or polycarbonate. Additional valve body materials 38 and 38A can be molded to improve the durability of the gas delivery assembly.

[0057] refer to Figure 5 The illustration shows another embodiment of the soldering apparatus. For example... Figure 5 As shown, the insulating material can be recessed to define notches 39 and 39A. This can be used where the electrode insulating material and the material constituting the device body require mechanical bonding rather than chemical bonding.

[0058] In some embodiments, the soldering apparatus may further include a buffer. A typical injection molding process requires placing an insulating electrode along with molten plastic in a mold cavity. During this process, the insulating material may deform in response to the high temperature of the molten plastic, resulting in reduced structural integrity. To maintain the structure of the insulating material, a buffer may be placed around the insulating electrode to inhibit deformation of the insulating material. The buffer material may include, but is not limited to, thermoplastics, metals, and wood. The buffer physically constrains the insulation to maintain its current shape and reduces heat transfer to the insulating material on the electrode, thereby helping the electrode insulation maintain its structure. The buffer may completely or partially cover the insulating material. In some embodiments, the buffer may have an inner diameter slightly larger than the diameter of the insulating material of the electrode, such that the buffer frictionally engages with the electrode insulation. In alternative embodiments, the insulating electrode may include notches, textures, and / or other features to inhibit movement of the buffer.

[0059] refer to Figure 6 , 7AThe embodiment depicted in 7B illustrates a buffer 60. The buffer may have one or more lugs 61A, 61B, 61C, 61D at one or both ends, these lugs configured to couple the buffer to the insulating material of the insulating electrode 62. The insulating material of the insulating electrode may define anti-rotation tabs 63A, 63B, 63C, 63D, which, when coupled to the lugs 61A, 61B, 61C, 61D, suppress movement of the buffer. The electrode 62 may optionally be formed to define the anti-rotation tabs. For example, the electrode may be formed to include fins 64, such as... Figure 7B The electrode is shown in the diagram. When the molded fin 64 is covered with an insulating material, the insulating material will adhere to the fin of the electrode to form an anti-rotation protrusion. In an alternative embodiment, the electrode may include notches, textures, and / or other features for suppressing the movement of the buffer.

[0060] refer to Figure 8 The paper describes an electric soldering device with a buffer element arranged around an insulating material. The device body material is overmolded onto the insulating electrode and the buffer element, forming a mechanical bond between the buffer element, the insulating material, and the device body material.

[0061] refer to Figure 9 The image depicts an electrocautery apparatus in which a gas tip 41 is formed of a third material different from the apparatus body material and the insulating material. The gas tip 41 is formed by overmolding and shaped to have a neck 42 to enhance the bond between the apparatus body material and the gas tip. In some embodiments, the gas tip has a notch on its upper portion. In such embodiments, the notch is held in place by the neck 42, thereby preventing the gas tip from decoupling from the apparatus body.

[0062] It may be advantageous to use a unique third material to form the gas end when the properties of the third material (e.g., strength, heat resistance, and / or similar properties) are superior to those of the device body material. The gas end may be made of metal, such as stainless steel. In some embodiments, the gas end may be welded to a distal end. Optionally, the third material forming the gas end may be coated with a polymer coating, such as a PTFE coating. In some embodiments, the gas end 41 is formed by compression molding.

[0063] refer to Figure 10 The image depicts a soldering apparatus with a low-profile body 51. A distal second portion 52 of the upper part of the valve body is angled to reduce the overall length and height of the gas delivery assembly while maintaining an acute angle and rearward distance relative to the distal end 12 of the electrode. In various embodiments, the gas delivery channel may extend parallel to the distal end and together with the distal end 12 of the electrode. In some embodiments, the gas delivery assembly can be angled to achieve a desired acute angle relative to the soldering blade.

[0064] refer to Figure 11 Another embodiment of the soldering apparatus is depicted, wherein a gas tube 61 is fluidly coupled to an assembly. The gas tube 61 is overmolded onto the assembly, and a chuck 62 holds the gas tube 61 in place and prevents movement when gas is supplied from a gas supply source. Fins 63 and 63A are overmolded onto the gas tube to help stabilize the tube within the gas supply connector of the soldering apparatus. In some embodiments, the gas tube 61 may be permanently coupled to the soldering apparatus. In such embodiments, the gas tube is permanently coupled to the gas supply connector of the soldering apparatus via overmolding. In some such embodiments, the gas tube is permanently coupled to the soldering apparatus by overmolding one or more materials onto at least a portion of the connection between the gas tube and the gas supply connector. In other embodiments, the gas tube is permanently coupled to the soldering apparatus by overmolding the gas tube with the device body material defining the gas supply connector. In other embodiments, the gas tube may be removable. In some embodiments, the gas tube is held in place by friction with a cavity at the gas supply connector.

[0065] refer to Figure 12 The image depicts an electrocautery device with an extended length. In this embodiment, the electrode 71 is elongated, and the gas end of the gas delivery assembly is positioned at an acute angle in the proximal direction at a distance of 3 mm to 10 mm from the distal end of the electrode of the electrocautery device.

[0066] refer to Figure 13 Another embodiment of a soldering apparatus with an extended length is depicted. In this embodiment, the upper part includes an elongated tube 81 defining a gas delivery channel. The elongated tube 81 is angled to reduce the body size and vertical profile of the soldering apparatus. An additional section 82 is overmolded with an insulating material formed onto the elongated tube and the soldering blade to increase the stability of the elongated tube.

[0067] refer to Figure 14 The image depicts a perspective view of an electrosurgical handheld device. The device includes a housing 91, a slot 92, buttons 93 and 93A, and a wire 94. The housing 91 is typically held by the operator. The slot 92 internally houses electrode fasteners for holding the electrodes. Buttons 93 and 93A control the current delivery to the electrodes. The wire 94 connects to a plug 95, which is intended for connection to an energy source such as an electrosurgical generator.

[0068] The handheld device allows the user to control the amount of power supplied to the electrodes and ultimately to the biological tissue. The optimal amount of power to supply depends on factors other than the desired surgical procedure, such as the size and width of the target tissue. The "cutting" mode is typically used to dissect muscles, subcutaneous fat, and fascia or membrane tissue. When the electrocautery device is used in cutting mode, power between 40 and 100 watts is applied to the tissue. The "coagulation" mode is typically used to stop bleeding around muscles or subcutaneous fat, but it can also be used to cut tissue near blood vessels and nerve bundles, as well as more sensitive fascia or membrane tissue. When the electrocautery device is used in coagulation mode, power between 20 and 60 watts is applied to the tissue.

[0069] refer to Figure 15 The image depicts an electrocautery device coupled to an electrosurgical handpiece. The lower part of the electrocautery device body is coupled to a groove in the electrosurgical handpiece and held in place by internal electrode fasteners within the handpiece. An overmolded electrode with a gas delivery assembly is rotatable relative to the handpiece.

[0070] refer to Figure 16 The paper describes a system for dissecting biological tissues. The system includes an electrocautery device 160, a gas supply source 101 coupled to a gas supply element of the electrocautery device via a gas supply tube 103, an energy supply source 102 configured to supply current to the electrodes of the electrocautery device, and a handheld device 161 operatively coupled to the energy supply source.

[0071] At a first end, the gas supply pipe 103 is connected to the soldering apparatus 104 via a gas supply connector. At a second end, the gas supply pipe 103 is connected to a nozzle 105 on a gas source. In various embodiments, the gas supply pipe is fluidly connected to one or both of the soldering apparatus 104 and the gas source nozzle 105 via a threaded adapter. A valve on the gas source 106 is used to control the airflow to the soldering blade.

[0072] The gas supply source can be a gas cylinder or other feeding device such as a box or regulator. Alternatively, the gas supply source can be a direct gas line. Alternative gas control systems can be used. Examples of such alternative gas control systems include a foot valve controller, a remote valve located next to the user of the soldering device, and any other gas control system. In some embodiments, the gas supplied by the gas supply source is an inert gas. In some such embodiments, the gas is carbon dioxide. In other embodiments, the gas supplied by the gas supply source is argon.

[0073] The gas tubing and gas supply source are not coupled to the energy supply source. Decoupling the gas and energy supply sources isolates damage caused by failure of either system. Coupler 107 is attached to the gas tubing and wiring to keep the system tidy and avoid potential harm to the user or damage to the system.

[0074] In some embodiments, the gas supply source and gas tubing are located externally to the handheld device and are visible to the operator. This allows for the identification of potential blockages or damage to the gas system.

[0075] Various embodiments of overmolded soldering blades with gas delivery components have been described and illustrated. Features of the several embodiments described herein can be combined without limitation.

[0076] Thanks to the teachings given in the foregoing description and the accompanying drawings, the modifications of the invention set forth herein will come to the mind of those skilled in the art. Therefore, it should be understood that the invention is not limited to the specific embodiments disclosed, and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terminology is used herein, it is used in a general and descriptive sense only and not for limiting purposes.

Claims

1. An electrocautery device for dissecting biological tissues, the electrocautery device comprising: Insulating electrode, the insulating electrode comprising: An electrode having a distal end configured to deliver an electric current to biological tissue and a proximal end configured to couple to an energy supply source; and An insulating material is radially disposed on the middle portion of the electrode, such that the distal and proximal ends of the electrode are not covered by the insulating material. A soldering device body, the soldering device body being formed of a device body material, the soldering device body comprising: The lower part, radially disposed on the insulating electrode; and The upper part, which is formed as a single integral part with the lower part and defines a gas delivery assembly, the gas delivery assembly comprising: A first portion, formed at the proximal end of the upper portion, includes a gas supply connector configured to receive gas from a gas supply source; and The second part, located distal to the first part, defines a gas delivery channel, and A gas terminal, said gas terminal being coupled to the distal end of the second portion and extending distally from said distal end of the second portion, The gas delivery channel is in fluid communication with the gas supply connector, such that when the gas supply source is coupled to the gas supply connector, the gas delivery channel is configured to deliver gas supplied by the gas supply source to the biological tissue via the gas end.

2. The soldering apparatus according to claim 1, characterized in that, The insulating electrode is formed by overmolding the insulating material onto the middle portion of the electrode.

3. The soldering apparatus according to claim 2, characterized in that, The insulating material is overmolded onto the middle portion of the electrode by injection molding.

4. The soldering apparatus according to claim 1, characterized in that, The body of the soldering device is formed by encapsulating the device body material onto the insulating electrode.

5. The soldering apparatus according to claim 1, characterized in that, The insulating material is overmolded onto the middle portion of the electrode by compression molding.

6. The soldering apparatus according to claim 1, characterized in that, The distal end is shaped into a blade.

7. The soldering apparatus according to claim 1, characterized in that, The gas supply connector includes a threaded connector.

8. The soldering apparatus according to claim 1, characterized in that, The gas supply connector includes a tapered connector configured to facilitate frictional engagement between the gas supply source and the gas supply connector.

9. The soldering apparatus according to claim 1, characterized in that, The insulating electrode further includes a buffer element disposed on the outer surface of the insulating material and configured to reduce or prevent deformation of the insulating material.

10. The soldering apparatus according to claim 9, characterized in that: The buffer includes one or more lugs at at least one end of the buffer; The insulating material includes anti-rotation tabs; and The lug and the anti-rotation tab are configured to interact such that the buffer is held in place by the anti-rotation tab.

11. The soldering apparatus according to claim 10, characterized in that, The anti-rotation tabs of the insulating material are defined by the shape of the insulating electrode.

12. The soldering apparatus according to claim 1, characterized in that: The proximal end of the electrode is configured to be coupled to a handheld device, which is operatively coupled to the power supply source. and The handheld device is configured to increase or decrease the amount of power supplied to the soldering device via the current when operated by a user.

13. The soldering apparatus according to claim 1, characterized in that, The gas terminal is formed of a third material that is different from the insulating material and the material of the device body.

14. The soldering apparatus according to claim 1, characterized in that, The gas end is disposed adjacent to the distal end of the insulating electrode.

15. The soldering apparatus according to claim 1, characterized in that, The second portion of the upper part of the soldering device body forms an acute angle with the lower part of the soldering device body.

16. The soldering apparatus according to claim 1, characterized in that, The second portion of the upper part of the soldering device body is inclined to the lower part of the soldering device body such that the angle between its proximal end and the lower part of the device body is smaller than the angle between its distal end and the lower part of the device body.

17. The soldering apparatus according to claim 1, characterized in that, The second portion of the upper part of the soldering device body is inclined to the lower part of the soldering device body, such that the angle between its proximal end and the lower part of the device body is greater than the angle between its distal end and the lower part of the device body.

18. A system for dissecting biological tissues, the system comprising: The soldering device includes: Insulating electrode, the insulating electrode comprising: An electrode having a distal end configured to deliver an electric current to biological tissue and a proximal end configured to couple to an energy supply source; and An insulating material is radially disposed on the middle portion of the electrode, such that the distal and proximal ends of the electrode are not covered by the insulating material. The soldering device body includes: The lower part, radially disposed on the insulating electrode; and The upper part, which is formed as a single integral part with the lower part and defines a gas delivery assembly, the gas delivery assembly comprising: A first portion, formed at the proximal end of the upper portion, includes a gas supply connector configured to couple to a gas supply source; and The second part, located distal to the first part, defines a gas delivery channel, and A gas terminal, said gas terminal being coupled to the distal end of the second portion and extending distally from said distal end of the second portion, The gas delivery channel is in fluid communication with the gas supply connector, such that when the gas supply source is coupled to the gas supply connector, the gas delivery channel is configured to deliver gas supplied by the gas supply source to the distal end of the soldering device. A gas supply source, which is coupled to the gas supply connector of the soldering device via a gas supply pipe; A power supply source configured to supply current to the electrodes of the soldering apparatus; and A handheld device, operatively coupled to the energy supply source, The handheld device is configured to increase or decrease the amount of power supplied to the soldering device via the current when operated by a user.

19. The system according to claim 18, characterized in that, It also includes a gas pump operatively coupled to the proximal end of the gas tube and configured to facilitate the movement of gas from the gas source to the gas delivery assembly of the soldering device.

20. The system according to claim 18, characterized in that, The gas supply tube is permanently coupled to the gas supply connector of the soldering device via overmolding.

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