Electrosurgical electrodes and electrosurgical tools for delivering electrical energy - Patents.com

Abstract

An electrosurgical tool for delivering electrical energy includes an elongated electrode extending axially from a proximal electrode end to a distal electrode end. The distal electrode end defines a working end configured to cut or coagulate tissue with electrical energy received by the electrosurgical tool. At least one layer of insulating material covers the exterior surface of the working end such that a portion of the exterior surface of the working end is not covered by the insulating material. When electrical energy is supplied to the elongated electrode, current flows only through the exposed portion of the exterior surface of the working end. The at least one layer of insulating material prevents current from straying from the exterior surface of the working end that is covered by the insulating material.

Description

[Technical field]

[0001] The present invention relates to electrosurgical electrodes and electrosurgical tools for delivering electrical energy.

[0002] CROSS-REFERENCE TO RELATED APPLICATIONS This application claims the benefit of priority to U.S. Provisional Application No. 62,934,489, filed November 12, 2019, and U.S. Provisional Application No. 62 / 854,803, filed May 30, 2019, the contents of which are incorporated by reference in their entireties herein.

[0003] The present disclosure relates generally to methods and apparatus for delivering electrical energy, and more particularly to electrosurgical tools having elongated electrodes that can be used to cut or coagulate tissue using electrical energy received by the elongated electrodes. [Background technology]

[0004] Electrosurgery involves the application of radio frequency (RF) current (also referred to as electrical energy) to biological tissue to cut, coagulate, or modify the tissue during an electrosurgical procedure. In particular, an electrosurgical generator generates and supplies an electrical current to an active electrode, which applies the current (and thus power) to the tissue. The current flows through the tissue and returns to the generator via a return electrode (also referred to as a "dispersive electrode") in the case of a monopolar system, or via a second active electrode in the case of a bipolar system. As the current flows through the tissue, the impedance of the tissue converts a portion of the current into thermal energy (e.g., by the principles of resistive heating), thereby increasing the temperature of the tissue and inducing modification of the tissue (e.g., cutting, coagulating, ablating, and / or sealing the tissue). Summary of the Invention [Problem to be solved by the invention]

[0005] For example, when tissue reaches a temperature of approximately 55 degrees Celsius (C), nearby cells die. As more current is applied, the temperature increases until the dead cells dry out and proteins coagulate. As more current is applied and the heat increases even more (over 100°C), the tissue remains vaporize. [Means for solving the problem]

[0006] In the example, an electrosurgical electrode for delivering electrical energy is described. The electrosurgical electrode includes a proximal electrode end configured to receive electrical energy from an electrosurgical tool, a distal electrode end, and an operative end portion (also called a working end portion or active end portion) between the proximal and distal electrode ends. The operative end portion is configured to cut or coagulate tissue using the electrical energy received by the proximal electrode end. The electrosurgical electrode further includes a first lateral surface (also called a first side), a second lateral surface (also called a second side) opposite the first lateral surface, a first face extending between the first and second lateral surfaces on a first side of the electrosurgical electrode, and a second face extending between the first and second lateral surfaces on a second side of the electrosurgical electrode opposite the first side.

[0007] The electrosurgical electrode further includes one or more apertures extending through the entire thickness of the elongated electrode between the first and second sides. The electrosurgical electrode also includes at least one layer of insulating material coupled to the exterior surface of the working end such that a first portion of the exterior surface is covered by the at least one layer of insulating material and a second portion of the exterior surface is not covered by the at least one layer of insulating material. The at least one layer of insulating material is configured to prevent application of electrical current from the first portion of the exterior surface to tissue of a patient. The at least one layer of insulating material is coupled to the exterior surface with the one or more apertures.

[0008] In another example, an electrosurgical electrode for delivering electrical energy is described. The electrosurgical electrode includes a proximal electrode end configured to receive electrical energy from an electrosurgical tool, a distal electrode end, and a working end portion between the proximal and distal electrode ends. The working end portion is configured to cut or coagulate tissue using the electrical energy received by the proximal electrode end. The electrosurgical electrode further includes a first lateral surface, a second lateral surface opposite the first lateral surface, a first face extending between the first and second lateral surfaces on a first side of the electrosurgical electrode, and a second face extending between the first and second lateral surfaces on a second side of the electrosurgical electrode opposite the first side. The electrosurgical electrode also includes a plurality of teeth on at least one of the first and second lateral surfaces, each of the plurality of teeth may be tapered to a respective tip point.

[0009] The features, functions, and advantages discussed above can be achieved independently in various examples or can be combined in still other examples, further details of which can be found in the following description and drawings.

[0010] The novel features which are believed to be characteristic of the illustrative examples are set forth in the appended claims. The illustrative examples, however, as well as the preferred mode of use, other objects and explanations thereof, will best be understood by reference to the following detailed description of illustrative examples of the present disclosure, read in connection with the accompanying drawings. [Brief description of the drawings]

[0011] [Figure 1] FIG. 1 illustrates an electrosurgical system for performing electrosurgery, according to an exemplary embodiment. [Diagram 2] FIG. 2 illustrates an electrosurgical pencil for use in an electrosurgical system such as the system shown in FIG. 1. [Diagram 3] 1 is a side view of an elongated electrosurgical electrode according to an exemplary embodiment. [Figure 4A]FIG. 4 is a cross-sectional view of the elongated electrosurgical electrode shown in FIG. 3. [Figure 4B] 4 is another cross-sectional view of the elongated electrosurgical electrode shown in FIG. 3. [Diagram 5] 1 is a side view of an elongated electrosurgical electrode according to an exemplary embodiment. [Figure 6] 1 is a perspective view of an elongated electrosurgical electrode according to an exemplary embodiment; [Figure 7] 7 is another perspective view of the elongated electrosurgical electrode shown in FIG. 6. [Figure 8] 1 is a perspective view of an elongated electrosurgical electrode according to an exemplary embodiment having a seamless insulating layer added thereto. [Figure 9] 9 is another perspective view of the elongated electrosurgical electrode shown in FIG. 8 with seamless insulating material added. [Figure 10] 1 is a perspective view of an elongated electrosurgical electrode according to an exemplary embodiment; [Figure 11] 11 is another perspective view of the elongated electrosurgical electrode shown in FIG. 10. [Figure 12] 1 is a perspective view of an elongated electrosurgical electrode according to an exemplary embodiment; [Figure 13] 13 is another perspective view of the elongated electrosurgical electrode shown in FIG. 12. [Figure 14] FIG. 1 illustrates another electrosurgical system for performing electrosurgery, according to an exemplary embodiment. [Figure 15A] 1 is a perspective view of an electrosurgical electrode according to an exemplary embodiment; [Figure 15B] FIG. 15B is a plan view of the electrosurgical electrode shown in FIG. 15A. [Figure 15C] FIG. 15B is a first side view of the electrosurgical electrode shown in FIG. 15A. [Figure 15D] FIG. 15B is a second side view of the electrosurgical electrode shown in FIG. 15A. [Figure 16A] 1 is a perspective view of an electrosurgical electrode according to an exemplary embodiment; [Figure 16B] FIG. 16B is a plan view of the electrosurgical electrode shown in FIG. 16A. [Figure 16C]FIG. 16B is a side view of the electrosurgical electrode 1600 shown in FIG. 16A. [Figure 17A] FIG. 13 is a plan view of an electrosurgical electrode according to another example. [Figure 17B] 17B is a cross-sectional view of the electrosurgical electrode shown in FIG. 17A, according to an example. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0012] The disclosed examples will now be described more fully with reference to the accompanying drawings, in which some, but not all, of the disclosed examples are shown. Indeed, several different examples may be described, and they should not be construed as being limited to the examples set forth herein. Rather, these examples are described so that this disclosure will be thorough and complete, and will fully convey the scope of the disclosure to those skilled in the art.

[0013] The terms "about" or "substantially" with reference to a quantity or measurement described herein mean that the described characteristic, parameter or value need not be achieved exactly, but rather that deviations or variations, including, for example, tolerance limits, measurement error limits, measurement precision limits, and other factors known to those of skill in the art, may occur in an amount that does not eliminate the effect that the characteristic was intended to provide.

[0014] While performing electrosurgery, the electrosurgical electrodes may apply some stray current to the tissue that is not used for the desired cutting or coagulation of the tissue. It would be advantageous to perform electrosurgery with reduced stray current. It would also be advantageous to have the desired current flow only through the desired cut site and reduce stray current, which would also produce less smoke, which in turn could further reduce undesirable airborne matter. The disclosed electrosurgical electrodes can be utilized to collect and direct current to the desired tissue target, while also facilitating the reduction of stray or undesirable non-cutting current.

[0015] In examples, electrosurgical electrodes of the present disclosure may collect and direct current in this manner by one or more geometric features of the electrosurgical electrode and / or one or more layers of insulating material covering select portions of the electrosurgical electrode. For example, the electrosurgical electrode may include a geometric feature at one or more edges to help increase current density at the edge. By way of example, the geometric feature may include a relatively fine edge (e.g., a relatively sharp edge) and / or a plurality of teeth each tapered to a relatively fine tip. Exemplary cutting edges may be machined (e.g., milled) or otherwise designed along at least a portion of the blade to exhibit a particular desired cleaving or cutting edge that focuses current toward a desired tissue target.

[0016] As used herein, the term "insulating material" means a material suitable for covering a portion of the exterior surface of an electrosurgical electrode and preventing the application of electrical energy from that portion of the exterior surface to the tissue of a patient. Thus, by adding insulating material to a first portion of an electrosurgical electrode and omitting insulating material from a second portion of the electrosurgical electrode, the electrical current applied to the tissue of a patient can be concentrated in the second portion of the electrosurgical electrode. In an embodiment, the second portion of the electrosurgical electrode may be at least one edge of the electrosurgical electrode.

[0017] Due to the geometric features and / or selectively added insulating materials, the electrosurgical electrodes disclosed herein can have low stray current, which is current that is not used for the desired cutting or coagulation of the target tissue. The electrosurgical electrodes can cause less collateral damage to the tissue surrounding the target tissue site. Another advantage of having low stray current and the desired current flowing only through the desired cutting site is that less smoke is also produced, thus further reducing undesirable airborne contaminants.

[0018] The electrosurgical electrodes disclosed herein can also provide improved cutting efficiency. Cutting efficiency can be improved using an electrosurgical electrode blade that facilitates the desired placement of insulating material along the exterior surface of the blade with one or more openings. One or more openings, gaps, slots and / or holes provided by the electrosurgical electrode blade will be used to promote adhesion of insulating material along the exterior surface of the blade. One intent of such openings etc. is to allow insulating material on one side to bond with insulating material on the other side to create a seamless ring of insulation that will not lift or delaminate.

[0019] The aperture or apertures may extend along a portion of the length of the blade. The aperture or apertures etc. may be provided near the edge of the blade. Alternatively or additionally, the aperture or apertures etc. may be provided at alternative locations away from the edge of the blade. By way of example, the aperture may comprise a slot having a thickness of approximately 125 microns.

[0020] As described above, the electrosurgical electrode may include at least one layer of insulating material covering selected portions of the exterior surface of the electrosurgical electrode. Covering selected portions of the exterior surface with at least one layer of insulating material presents technical challenges in that the insulating material may become decoupled from the electrosurgical electrode during or after the electrosurgical procedure. For example, in some instances, if the at least one layer of insulating material does not extend around the entire circumference of the electrosurgical electrode, the at least one layer of insulating material may have a free edge that may contact tissue during the electrosurgical procedure. When tissue contacts the free edge of the at least one insulating layer, the tissue may apply a force to the free edge that causes the free edge to become decoupled from the exterior surface of the electrosurgical electrode.

[0021] In examples, the electrosurgical electrodes described herein can address this technical problem associated with covering select portions of the electrosurgical electrode with at least one layer of insulating material. In particular, in examples, the electrosurgical electrode can include one or more openings that can receive the at least one layer of insulating material and / or that extend through the entire thickness of the electrosurgical electrode such that the at least one layer of insulating material can extend through the one or more openings. In this manner, the one or more openings can provide a passageway through which the at least one layer of insulating material can extend such that the at least one layer of insulating material can extend between opposing sides of the electrosurgical electrode (e.g., as a continuous loop of insulating material).

[0022] In this configuration, when tissue applies a force to the at least one layer of insulating material, the portion of the at least one layer of insulating material extending through the one or more apertures forces (presses) the at least one layer of insulating material toward the exterior surface of the electrosurgical electrode. The one or more apertures can thus help inhibit or prevent the at least one layer of insulating material from becoming decoupled (separated) from the electrosurgical electrode.

[0023] The exemplary electrosurgical electrodes described herein can be used with a variety of different types of radio frequency (RF) electrosurgical systems, including monopolar and bipolar electrosurgical systems.

[0024] 1, an example electrosurgical system 200 is shown. In FIG. 1, electrosurgical system 200 is a monopolar electrosurgical system. However, as described in further detail below in connection with FIG. 14, the concepts of the present disclosure may additionally or alternatively be implemented in a bipolar electrosurgical system.

[0025] 1 , electrosurgical system 200 includes an electrosurgical electrode 210, a dispersive electrode 220, an RF generator 230, and an electrosurgical tool 240. RF generator 230 is configured to generate a current 250 suitable for performing an electrosurgical procedure on a patient. For example, RF generator 230 can include a power converter circuit capable of converting grid power into electrical energy, such as RF output power. By way of example, the power converter circuit can include one or more electrical components (e.g., one or more transformers) that can control the voltage, current, and / or frequency of the electrical energy.

[0026] Electrosurgical tool 240 can include electrosurgical electrode 210 and can include one or more electrical components configured to supply current 250 from RF generator 230 to electrosurgical electrode 210. As described in further detail below, electrosurgical electrode 210 can then use this current to supply electrical energy to the patient's tissue.

[0027] The dispersive electrode 220 can be coupled to the patient's body and to an RF generator 230. In this configuration, the RF generator 230 can supply current to the electrosurgical electrode 210, the electrosurgical electrode 210 can apply current to tissue, the tissue can conduct the current to the dispersive electrode 220, and the dispersive electrode 220 can return the current to the RF generator 230.

[0028] In the example, electrosurgical system 200 can be used for at least one treatment modality selected from a group of modalities including cutting, coagulation, and fulguration. In Figure 1, a surgeon 260 using an electrosurgical tool 240 (e.g., an electrosurgical pencil) including an electrosurgical electrode 210 places the electrosurgical electrode 210 adjacent to patient tissue to cut the tissue and also to coagulate bleeding in the patient.

[0029] The current from the electrosurgical electrode 210 develops a high temperature region around the exposed end of the electrosurgical electrode 210, which affects tissue. As described in detail herein, the disclosed electrosurgical electrode 210 reduces undesirable stray currents from the exposed end of the electrosurgical electrode 210, thus limiting unintended damage / destruction of tissue. This also tends to reduce the buildup of undesirable eschar and smoke (e.g., undesirable smoke particles).

[0030] Figure 2 illustrates a close-up view of an electrosurgical tool 300 for delivering electrical energy for use in a monopolar electrosurgical system, according to an example. For example, the electrosurgical tool 300 may be used in the monopolar electrosurgical system 200 shown in Figure 1. An alternative electrosurgical tool 300 may be used in a bipolar electrosurgical system, such as the bipolar electrosurgical system 1000 shown in Figure 14 and described herein.

[0031] In the configuration of FIG. 2 shown, electrosurgical tool 300 is in the form of an electrosurgical pencil. Thus, in FIG. 2, electrosurgical pencil 310 has an elongated shape that facilitates holding electrosurgical tool 300 by a user in the manner in which one holds a writing implement. However, electrosurgical tool 300 may have different shapes and / or sizes in other examples. More generally, electrosurgical tool 300 may be configured to facilitate gripping and handling of electrosurgical tool 300 by a user while performing an electrosurgery procedure. Electrosurgical tool 300 may thus be manually manipulated by a surgeon to cut or coagulate tissue with RF power, as described above.

[0032] 2, electrosurgical pencil 310 extends generally from a first or distal end 315 to a second or proximal end 320. Electrosurgical pencil 310 includes an elongated housing structure 330 that can be used to house certain electrosurgical pencil components. Distal end 315 of elongated housing structure 330 receives electrosurgical electrode 340. Electrosurgical electrode 340 can include a metal tip 345 that is used to cut or coagulate tissue during a surgical procedure. In one example, metal tip 345 includes a sharpened metal tip. In another example, metal tip 345 can include a blade-type structure having one or more machined cutting edges, as described in more detail herein. An insulating sleeve or insulating cover 371 can be provided near a proximal portion 380 of electrosurgical electrode 340. Insulating covering 371 may be made from a material that prevents electrosurgical electrode 340 from passing electrical energy to tissue through the portion of electrosurgical electrode 340 that is covered by insulating covering 371. In one example, electrosurgical electrode 340 is configured to be removably coupled to electrosurgical pencil 310.

[0033] The elongated housing structure 330 of the electrosurgical tool 300 may also define a number of windows or cavities 350a, 350b. These windows or cavities 350a, 350b may be defined to receive one or more human interface devices 360a, 360b. In an example, the elongated housing structure 330 includes a first cavity 350a and a second cavity 350b for receiving a first human interface device 360a and a second human interface device 360b, respectively. As an example, the individual human interface devices 360a, 360b may be utilized to perform a particular electrosurgical function, such as cutting or coagulating tissue. In an example, the first human interface device 360a may be used to coagulate, while the second human interface device 360b may be used to cut. Other human interface device configurations may also be used.

[0034] Electrosurgical tool 300 also includes an insulated cable 370 that supplies power to electrosurgical electrode 340. This insulated cable 370 can receive power from an RF generator, such as the RF generators shown in Figures 1 and 14. Alternatively, electrosurgical pencil 310 can include a separate power source, such as an internal power supply.

[0035] Figure 3 illustrates an electrosurgical electrode 400 that may be used with the electrosurgical tool 300 shown in Figure 2, according to an example. Figure 4A illustrates a first cross-sectional view of the electrosurgical electrode 400 shown in Figure 3, and Figure 4B illustrates a second cross-sectional view of the electrosurgical electrode 400 shown in Figure 3, according to an example.

[0036] 3-4B, electrosurgical electrode 400 extends axially along a longitudinal axis from a proximal electrode end 410 to a distal electrode end 420. As shown in FIG 4A, the distance between the proximal electrode end 410 and the distal electrode end 420 can define a length 413 of electrosurgical electrode 400. In examples, length 413 between proximal electrode end 410 and distal electrode end 420 can be between approximately 65 mm and approximately 75 mm. However, alternative distances can be used.

[0037] Electrosurgical electrode 400 also includes a first lateral surface 421 and a second lateral surface 422 extending between proximal electrode end 410 and distal electrode end 420. As shown in FIGURE 4B, the distance between first lateral surface 421 and second lateral surface 422 can define a width 417 of electrosurgical electrode 400.

[0038] Electrosurgical electrode 400 further includes a first major surface 423 and a second major surface 427 opposite first major surface 423 of electrosurgical electrode 400. First major surface 423 and second major surface 427 each extend (i) between proximal electrode end 410 and distal electrode end 420 and (ii) between first lateral surface 421 and second lateral surface 422. As shown in FIG. 4B, the distance between first major surface 423 and second major surface 427 can define a thickness 419 of electrosurgical electrode 400. As shown in FIG. 4B, thickness 419 can vary across width 417 of electrosurgical electrode 400.

[0039] In one example, the electrosurgical electrode 400 includes a working end portion 425 between the proximal electrode end 410 and the distal electrode end 420. The working end portion 425 is configured to cut and / or coagulate tissue using electrical energy received by an electrosurgical tool, such as the electrosurgical tool 300 shown in FIG. 2. Additionally, the electrosurgical tool may receive such electrical energy by an RF power source, such as the RF generator 230 shown in FIG. 1 or the RF generator 1100 shown in FIG. 14. In one example, the working end portion 425 of the electrosurgical electrode 400 includes a sharp or pointed tip at the distal electrode end 420 of the electrosurgical electrode 400. Alternatively, the working end portion 425 may include a blade-type structure having at least one beveled edge for cutting tissue. Other electrode working end configurations may also be used.

[0040] In an example, at least one layer of insulating material 440 covers a portion of the exterior surface 430 of the working end portion 425, and the at least one layer of insulating material 440 does not cover a second portion 435 of the working end portion 425. In this configuration, the second portion 435 of the exterior surface 430 of the working end portion 425 remains uncovered by the at least one layer of insulating material 440. In one example, the working end portion 425 of the electrosurgical electrode 400 is approximately 55 mm 2 and the insulating material 440 may comprise about 70 percent to about 80 percent of the total surface area (e.g., about 42 mm 2 ) can be covered.

[0041] As used herein, the term "insulating material" refers to a material suitable for covering a portion of the exterior surface 430 and preventing the application of electrical energy from that portion of the exterior surface 430 to the patient's tissue. In this manner, when electrical energy is supplied to the electrosurgical electrode 400, electrical current is conducted to the target tissue substantially only through the exposed select portion 435 of the exterior surface 430 of the working end portion 425 of the electrosurgical electrode 400. Similarly, the at least one layer of insulating material 440 acts to prevent electrical current from straying from the exterior surface 430 of the working end portion 425 that is covered by the insulating material 440. Thus, the insulating material 440 reduces certain undesirable effects that may result from stray currents generated by the electrosurgical electrode 400 during an electrosurgical procedure. Furthermore, any buildup of scabbing does not affect the performance of the insulated electrode as much as a typical non-insulated blade, where the buildup of scabbing may occur in a relatively similar thickness across the top of both the insulated and non-insulated electrode surfaces. Because electrical current seeks the path of least resistance, in the former case the electricity will be forced through the solidified scab, while in the latter case the current that is inhibited by the scab will instead flow through another current path of least resistance, acting as a stray current flowing through unintended tissue.

[0042] In one example, at least one layer of insulating material 440 comprises a polymeric material. For example, the thickness of at least one layer of insulating material 440 may comprise at least approximately 100 microns of insulating material. In the structure shown in FIGS. 3-4B, a single layer of insulating material 440 of 120 microns is provided to substantially cover working end portion 425 of electrosurgical electrode 400. However, in alternative electrosurgical electrode structures, it is also possible to provide one or more such layers along at least one portion of electrosurgical electrode 400. By way of example only, a first portion of electrosurgical electrode 400 may comprise a first layer of insulating material 440, while a second portion of electrosurgical electrode 400 may comprise both a first layer and a second layer of insulating material 440.

[0043] In one example, the polymeric material includes a fluorocarbon material. Exemplary fluorocarbon materials include polytetrafluoroethylene (PTFE). As mentioned above, the layer of insulating material 440 can have a thickness of at least 100 microns. This range of thickness is generally suitable to ensure that the polymeric material prevents application of electrical current as described above. However, other insulating materials can additionally or alternatively be used. For example, insulating material 440 can be silicone, polyolefin, and / or polyamide having a thickness sufficient to prevent application of electrical energy to tissue. Generally, the thickness of such alternative materials is suitable to prevent application of electrical current, and in some embodiments, the thickness can differ from the thickness range described above for the polymeric material.

[0044] In some examples, the insulating material 440 can have a constant thickness across the surface area of ​​the portion of the exterior surface 430 covered by the at least one layer of insulating material 440. The at least one layer of insulating material 440 having a constant thickness can be formed, for example, by subjecting the electrosurgical electrode 400 to an overmolding process, spray coating, and / or dip coating using a mask to prevent bonding of the insulating material 440 to the selected portions 435 to be exposed. The at least one layer of insulating material 440 having a constant thickness can facilitate reduced manufacturing complexity and / or facilitate reduced or prevented dielectric breakdown of the at least one layer of insulating material 440.

[0045] In other examples, insulating material 440 can have a variable thickness such that the thickness of the insulating material varies across the surface area of ​​the portion of exterior surface 430 covered by at least one layer of insulating material 440. At least one layer of insulating material 440 having a variable thickness can be formed by, for example, overmolding, dip coating, spray coating, and / or vapor deposition. In some embodiments, at least one layer of insulating material 440 having a variable thickness can be formed by variations in the shape of electrosurgical electrode 400 and as a result of particular manufacturing techniques.

[0046] In some examples, the at least one layer of insulating material 440 can include a single layer of a single type of insulating material. In other examples, the at least one layer of insulating material 440 can include a combination of multiple insulating materials and / or multiple insulating layers. By way of example only, a first layer of a first type of insulating material can be provided (e.g., a first layer of a first type of polymeric material) and a second layer of a second type of insulating material can be provided (e.g., a second layer of a second type of polymeric material different from the first type of polymeric material).

[0047] In the example shown in Figures 3-4B, second portion 435 is shown uncovered by at least one layer of insulating material 440, with the underlying conductive substrate of electrosurgical electrode 400 exposed. In other examples, however, the conductive substrate of electrosurgical electrode 400 may be covered by second portion 435 with one or more layers of a material that does not prevent application of electrical energy to tissue (e.g., a non-stick coating). For example, second portion 435 may be covered by one or more layers of a material described above for insulating material 440, but with a relatively thinner thickness suitable to permit passage of electrical energy from second portion 435 to tissue through the one or more layers of material.

[0048] As described above, electrosurgical electrode 400 may include at least one layer of insulating material 440 covering selected portions of exterior surface 430 of electrosurgical electrode 400. Covering selected portions of exterior surface 430 with at least one layer of insulating material 440 presents a technical challenge in that insulating material 440 may become decoupled from the electrosurgical electrode 400 during or after the electrosurgical procedure. For example, in some instances, if at least one layer of insulating material 440 does not extend around the entire circumference of electrosurgical electrode 400, at least one layer of insulating material 440 may have a free edge that may contact tissue during the electrosurgical procedure. When tissue contacts the free edge of at least one layer of insulating material 440, the tissue may apply a force to the free edge that causes the free edge to become decoupled from exterior surface 430 of electrosurgical electrode 400.

[0049] In examples, the electrosurgical electrodes described herein may address this technical problem associated with covering select portions of the electrosurgical electrode 400 with at least one layer of insulating material. In particular, in examples, the electrosurgical electrode may include one or more apertures that may receive the at least one layer of insulating material and / or extend through the entire thickness of the electrosurgical electrode such that the at least one layer of insulating material may extend through the one or more apertures. In this manner, the one or more apertures may provide a passageway through which the at least one layer of insulating material may extend such that the at least one layer of insulating material may extend between opposing sides of the electrosurgical electrode (e.g., as a continuous loop of insulating material).

[0050] In this configuration, when tissue applies a force to the at least one layer of insulating material, the portion of the at least one layer of insulating material extending through the one or more apertures forces (presses) the at least one layer of insulating material toward the exterior surface of the electrosurgical electrode. The one or more apertures can thus help inhibit or prevent the at least one layer of insulating material from becoming decoupled (separated) from the electrosurgical electrode.

[0051] Additionally, the one or more apertures in the electrosurgical electrode may allow at least one layer of insulating material to be formed on the exterior surface using manufacturing techniques that may be inappropriate for prior coatings (e.g., non-stick coatings) of the electrosurgical electrode. For example, the one or more apertures may allow the insulating material to become a solid structure that is bonded around a portion of the electrosurgical blade in a manner that allows the insulating material to play a role between the insulating material and the exterior surface of the electrosurgical electrode.

[0052] The one or more apertures in the electrosurgical electrode may additionally or alternatively simplify manufacturing and / or reduce the manufacturing costs of the electrosurgical electrode. For example, some existing electrosurgical electrodes that include a coating (e.g., a non-stick coating) may be manufactured by a process that includes a step of texturing a substantial portion of the exterior surface of the electrosurgical electrode prior to applying the coating to the electrosurgical electrode. In some embodiments, the surface texturing process is performed to promote adhesion of the coating to the exterior surface of the electrosurgical electrode. The surface texturing process may include, for example, an acid etching and / or sandblasting process to form and / or reinforce microscale and / or nanoscale peaks and valleys on the exterior surface of the electrosurgical electrode. Because the one or more apertures may promote bonding of an insulating material to the electrosurgical electrode, a process for manufacturing an electrosurgical electrode may optionally omit the surface texturing process.

[0053] However, in some examples, the manufacturing process for forming the electrosurgical electrodes described herein may include the surface texturing process described above to further enhance the engagement between the exterior surface of the electrosurgical electrode and the insulating material. Additionally or alternatively, the process for manufacturing the electrosurgical electrode may include forming a textured surface on the interior surface within the one or more apertures. This may facilitate improved engagement, for example, between the insulating material and the exterior surface of the electrosurgical electrode in the one or more apertures. One or more apertures described herein may be incorporated into any and all examples shown in the drawings and described herein. In some examples described above and below, one or more apertures and / or insulating material may not be explicitly shown in the figures to facilitate a clearer illustration and description of other features. However, one or more apertures and / or at least one layer of insulating material described and / or shown for any example herein may be incorporated into any other example described and shown in the present disclosure.

[0054] Figure 5 illustrates, by way of example, an electrosurgical electrode 600 for use with an electrosurgical tool for delivering electrical energy, such as electrosurgical tool 300 shown in Figure 2. As will be explained, the electrosurgical electrode 600 can be used for both cutting and coagulation.

[0055] Similar to electrosurgical electrode 400 described above, electrosurgical electrode 600 extends axially along a longitudinal axis from a proximal electrode end 610 to a distal electrode end 620. Electrosurgical electrode 600 also includes a first lateral surface 621 and a second lateral surface 622 extending from the proximal electrode end 610 to the distal electrode end 620. Electrosurgical electrode 600 further includes first and second major surfaces 623 and 624 (not shown in FIG. 5 ) each extending (i) between the proximal electrode end 610 and the distal electrode end 620 and (ii) between the first lateral surface 621 and the second lateral surface 622. In this configuration, electrosurgical electrode 600 has a length, width and thickness defined as described above.

[0056] In FIG. 5, the first lateral surface 621 of the electrosurgical electrode 600 comprises a smooth or generally straight surface. The second lateral surface 622 of the electrosurgical electrode 600 defines a sharp or machined beveled surface that defines a cutting edge 630. In one configuration, the cutting edge 630 will have a fine edge that will not be sharp enough to mechanically cut tissue but will focus electricity. By way of example only, the fine edge can have an edge thickness in the range of about 70 microns to about 200 microns. The curved surface in conjunction with the first lateral surface 621 can further define a fine tip 631 of the electrosurgical electrode 600.

[0057] The second lateral surface 622 includes a cutting edge 630. The cutting edge 630 can be configured to cut and coagulate tissue via electrical energy received by the conductive electrode 600, as described herein in connection with the electrosurgical system shown in Figures 1 and 14. An insulating member 640 in the form of a sleeve or cover is provided adjacent the proximal electrode end 610. For example, such an insulating member 640 can comprise an insulating heat shrink wrapping. The insulating member 640 can be formed from an insulating material that prevents transmission of electrical energy to tissue in the portion of the electrosurgical electrode 600 covered by the insulating member 640.

[0058] In this example, electrosurgical electrode 600 further defines an aperture 650. In the example shown in FIG. 5, aperture 650 is formed as a slot through the thickness of electrosurgical electrode 600. By way of example, the thickness of electrosurgical electrode 600 may range from about 0.45 mm to about 0.25 mm. However, alternative thicknesses may be used. In the configuration shown, aperture 650 extends along the length and also along the curvature defined by bottom or cutting edge 630. In electrosurgical electrode 600 shown in FIG. 5, first aperture 650 has a generally constant thickness to accommodate insulating material 660. However, in alternative configurations, aperture 650 may have a non-constant thickness.

[0059] The opening 650 is configured to receive an insulating material 660, such as the insulating material shown and described herein in connection with Figures 3 and 4. In this example, the insulating material 660 can be introduced or enveloped along an exterior surface 670 of the electrosurgical electrode 600 such that only the cutting edge 630 of the exterior surface portion of the working end portion 625 remains uncovered by the insulating material 660. For example, a portion 665 of the exterior surface 670 of the cutting edge 630 of the electrosurgical electrode 600 remains uncovered by the insulating material 660.

[0060] Although the electrosurgical electrode 600 includes only a single aperture 650 as shown in FIG. 5, the electrosurgical electrode 600 may be utilized in alternative configurations. By way of example only, the electrosurgical electrode 600 may define multiple apertures 650. In an exemplary conductive electrode with two or more apertures 650, the apertures 650 may have similar geometric configurations or different geometric configurations. For example, a conductive electrode with multiple apertures 650 may include multiple apertures 650 that are substantially the same in thickness but may vary in length. Similarly, the apertures 650 may include multiple slots that are substantially similar in length but may vary in thickness. Alternative geometric aperture 650 configurations may also be used, such as circular, triangular, oval, trapezoidal, or semicircular slot configurations.

[0061] 5, the cutting edge 630 may have a beveled edge and extend along the entire length of the conductive blade portion. In this example, the length of the conductive blade portion initially extends horizontally and then curves toward the distal-most tip portion 631 of the blade, thus providing an enhanced cutting edge. Alternative cutting edge configurations, such as a paddle-shaped electrode with at least one cutting edge, may also be utilized.

[0062] 5, electrosurgical electrode 600 includes at least one layer of insulating material 660 provided along an exterior surface of working end portion 625 such that only a select portion 665 of the exterior surface 670 of working end portion 625 is exposed. Thus, when electrical energy is supplied to electrosurgical electrode 600, electrical current can flow only through the exposed portion 665 of the exterior surface 670 of distal electrode tip 620. Thus, the at least one layer of insulating material 660 inhibits or prevents stray electrical current from flowing through the exterior surface 670 of working end portion 625 that is covered by insulating material 660.

[0063] 5, the portion 665 of the exterior surface 670 of the electrosurgical electrode 600 that is exposed includes the first major side 623 and at least a portion of the exterior surface 670 of the second major side and the cutting edge 630. As shown in FIG. 5, the portion 665 of the exterior surface 670 of the electrosurgical electrode 600 that is exposed additionally or alternatively includes the tip 631 of the electrosurgical electrode 600.

[0064] In one example, the insulating material 660 shown in FIG. 5 includes a polymeric material. The polymeric material can include a fluorocarbon material. In one example, the fluorocarbon material includes polytetrafluoroethylene (PTFE). Alternative insulating / polymeric materials can also be used. In one example, the insulating material 660 has a thickness of at least approximately 100 microns. In one example, the cutting edge 630 of the working end portion 625 comprises a longitudinal cutting edge. The longitudinal cutting edge of the working end portion 625 can extend along the entire length of the working end portion 625.

[0065] In some examples, the at least one layer of insulating material 660 may be a coating. In other examples, the at least one layer of insulating material 660 may be a solid structure that is bonded around a portion of electrosurgical electrode 600 in a manner that allows for some interaction between the at least one layer of insulating material 660 and the exterior surface 670 of electrosurgical electrode 600. For example, the at least one layer of insulating material 660 may form a continuous loop that extends through opening 650.

[0066] In some implementations, the at least one layer of insulating material 660 may be bonded to the exterior surface 670 only by engagement between the at least one layer of insulating material 660 and the exterior surface 670 at the opening 650. This may be in contrast to alternative embodiments in which the at least one layer of insulating material is attached and / or bonded to the exterior surface 670 on the first side 616 and / or the second side.

[0067] Figure 6 illustrates a perspective view of another example elongated electrosurgical electrode 700. The elongated electrosurgical electrode 700 may be used with an electrosurgical tool for delivering electrical energy, such as the electrosurgical tool 300 illustrated in Figure 2. Figure 7 illustrates another perspective view of the elongated electrosurgical electrode 700 illustrated in Figure 6.

[0068] Similar to electrosurgical electrodes 400, 500, 600 described above, electrosurgical electrode 700 extends axially along a longitudinal axis from a proximal electrode end 710 to a distal electrode end 720. Electrosurgical electrode 700 also includes a first lateral surface 721 and a second lateral surface 722 extending from the proximal electrode end 710 to the distal electrode end 720. Electrosurgical electrode 700 further includes a first major surface 723 and a second major surface 727 each extending (i) between the proximal electrode end 710 and the distal electrode end 720 and (ii) between the first lateral surface 721 and the second lateral surface 722. In this configuration, electrosurgical electrode 700 has a length, width and thickness defined as described above.

[0069] The first major surface 723 of the electrosurgical electrode 700 (FIG. 6) includes a smooth or generally straight surface. The second major surface 727 of the electrosurgical electrode 700 (FIG. 7) also includes a smooth or generally straight surface. In one configuration, the first major surface 723 and the second major surface 727 are configured parallel to one another and are tapered toward one another and meet to define a beveled sharp outer electrode perimeter (outer electrode edge) or a beveled machined outer electrode perimeter 733. This outer electrode perimeter 733 defines a cutting edge 730 that extends along the perimeter 733 of the electrosurgical electrode 700. In one configuration, the cutting edge 730 will include a fine edge 732 that will focus electricity but will not be sharp enough to mechanically cut tissue. By way of example only, the fine edge 732 can have an edge thickness in the range of about 70 microns to about 200 microns. The fine edges 732 can be configured to cut and coagulate tissue via electrical energy received by the conductive electrode 700, as described herein in connection with the electrosurgical systems shown in Figures 1 and 14.

[0070] In this example, electrosurgical electrode 700 further defines a first opening 750a and a second opening 750b. First opening 750a comprises a first slot through the thickness of electrosurgical electrode 700. By way of example only, the thickness of electrosurgical electrode 700 may range from about 0.45 mm to about 0.25 mm. However, alternative thicknesses may be used. In the construction shown, first opening 750a extends along a length defined by first portion 740a of cutting edge 730. In electrosurgical electrode 700 shown in FIGS. 6 and 7, first opening 750a has a generally constant thickness to accommodate insulating materials as described herein. However, in alternative constructions, first opening 750a may have a non-constant thickness.

[0071] Similarly, in the example shown, second opening 750b comprises a second slot through the thickness of electrosurgical electrode 700. In the configuration shown, second opening 750b extends along a length defined by second portion 740b of cutting edge 730. In electrosurgical electrode 700 shown in Figures 6 and 7, second opening 750b has a generally constant thickness to accommodate insulating materials as described herein. However, in alternative configurations, second opening 750b can have a non-constant thickness.

[0072] First opening 750a and second opening 750b are configured to receive an insulating material, such as the insulating material shown and described herein with respect to Figures 3-5. For example, Figure 8 shows a perspective view of electrosurgical electrode 700 with insulating material 760. Figure 9 shows another perspective view of electrosurgical electrode 700 shown in Figure 8. In the example shown, insulating material 760 may be bonded to or wrapped along an exterior surface 770 of electrosurgical electrode 700 (see Figures 6 and 7) such that only a first portion 740a of cutting edge 730, a second portion 740b of cutting edge 730, and a third portion 740c of cutting edge 730 of the exterior portion of working end portion 725 remain uncovered by insulating material 760.

[0073] Figure 10 illustrates a perspective view of an exemplary embodiment of an elongated electrosurgical electrode 800. Figure 11 illustrates another perspective view of the elongated electrosurgical electrode 800 shown in Figure 10.

[0074] Similar to electrosurgical electrodes 400, 500, 600, 700 described above, electrosurgical electrode 800 extends axially along a longitudinal axis from a proximal electrode end 810 to a distal electrode end 820. Electrosurgical electrode 800 also includes a first lateral surface 821 and a second lateral surface 822 extending from the proximal electrode end 810 to the distal electrode end 820. Electrosurgical electrode 800 further includes a first major surface 823 and a second major surface 827 each extending (i) between the proximal electrode end 810 and the distal electrode end 820 and (ii) between the first lateral surface 821 and the second lateral surface 822. In this configuration, electrosurgical electrode 800 has a length, width and thickness defined as described above.

[0075] The first major surface 823 of the electrosurgical electrode 800 (FIG. 10) comprises a smooth or generally straight surface. The second major surface 827 of the electrosurgical electrode 800 (FIG. 11) also comprises a smooth or generally straight surface. In one configuration, the first major surface 823 and the second major surface 827 are configured parallel to one another and are tapered toward one another to meet and define a beveled sharp outer electrode perimeter or a beveled machined outer electrode perimeter 833. The outer electrode perimeter 833 defines a cutting edge 830 that extends along the perimeter 833 of the electrosurgical electrode 800. In one configuration, the cutting edge 830 will comprise a fine edge 832 that will focus electricity but will not be sharp enough to mechanically cut tissue. By way of example only, the fine edge 832 can have an edge thickness in the range of about 70 microns to about 200 microns. Preferably, the fine edge 832 can be configured to cut and coagulate tissue via electrical energy received by the conductive electrode 800, as described herein in connection with the electrosurgical system shown in Figures 1 and 14.

[0076] In this example, the electrosurgical electrode 800 further defines a plurality of apertures 850 extending through a thickness of the electrosurgical electrode 800. By way of example only, the thickness of the electrosurgical electrode 800 may range from approximately 0.45 mm to approximately 0.25 mm. However, alternative thicknesses may be used. In this configuration shown, the plurality of apertures 850 are arranged in an ordered series or arrangement (e.g., an array of circular apertures arranged in multiple rows) extending along the length L840 of the cutting edge 830. However, alternative aperture arrangements may also be used, such as a plurality of apertures arranged in a non-ordered series or arrangement extending along the length L840 of the cutting edge 830, or at least a portion thereof (see FIG. 10).

[0077] In the electrosurgical electrode 800 shown in Figure 10, each of the plurality of apertures 850 comprises a circular aperture, with each circular aperture having a uniform or constant circumference or radius. However, in alternative circular aperture arrangements, one or more of the circular apertures can have a non-uniform or non-constant circumference or radius.

[0078] The plurality of openings 850 are configured to receive an insulating material, such as the insulating material shown and described herein in connection with Figures 3 and 4 and generally described in connection with Figures 8 and 9. In such an example, the insulating material may be introduced or enveloped along the exterior surface 870 of the electrosurgical electrode 800 such that only the first portion 840a of the cutting edge 830, the second portion 840b of the cutting edge 830, and the third portion 840c of the cutting edge 830a of the exterior portion of the working end portion 825 remain free of the insulating material, similar to the elongated electrode configuration shown in Figures 8 and 9. The one or more openings provided by the electrosurgical electrode 800 may be used to promote the anchoring of the insulating material along the exterior surface 870 of the electrosurgical electrode 800. One intent of the openings 850 is to allow the insulating material of the first major surface 823 to be combined with the insulating material of the second major surface 827 to produce a seamless ring of insulating material that does not tend to lift or delaminate. Alternative geometric aperture configurations may also be used, such as triangular, oval, trapezoidal or semicircular aperture configurations.

[0079] 12 illustrates a perspective view of an exemplary embodiment of an elongated electrosurgical electrode 900. FIGURE 13 illustrates another perspective view of the elongated electrosurgical electrode 900 shown in FIGURE 12.

[0080] Similar to electrosurgical electrodes 400, 500, 600, 700, 800 described above, electrosurgical electrode 800 extends axially along a longitudinal axis from a proximal electrode end 910 to a distal electrode end 920. Electrosurgical electrode 900 also includes a first lateral surface 921 and a second lateral surface 922 extending from the proximal electrode end 910 to the distal electrode end 920. Electrosurgical electrode 900 further includes a first major surface 923 and a second major surface 927 each extending (i) between the proximal electrode end 910 and the distal electrode end 920 and (ii) between the first lateral surface 921 and the second lateral surface 922. In this configuration, electrosurgical electrode 900 has a length, width and thickness defined as described above.

[0081] As shown in Figures 12 and 13, the electrosurgical electrode 900 has a working end portion 925 in the form of a circular head. The first major surface 923 of the electrosurgical electrode 900 (Figure 12) has a smooth or generally straight surface. The second major surface 927 of the electrosurgical electrode 900 (Figure 13) also has a smooth or generally straight surface. In one configuration, the first major surface 923 and the second major surface 927 are configured parallel to one another and are tapered toward one another and meet to define a beveled sharp outer electrode perimeter or a beveled machined outer electrode perimeter 933. This outer electrode perimeter 933 defines an edge 930 that extends along the circumference of the electrosurgical electrode 900. In one configuration, this edge 930 has a cutting edge that will not be sharp enough to mechanically cut tissue but will have a fine edge that will focus electricity. By way of example only, the fine edge may have an edge thickness within the range of about 70 microns to about 200 microns. Preferably, the fine edge may be configured to cut and coagulate tissue via electrical energy received by the conductive electrode 900, as described herein in connection with the electrosurgical system shown in Figures 1 and 14.

[0082] In this example, electrosurgical electrode 900 is located in a generally central portion of the circular head and further defines a plurality of apertures 950 through a thickness of electrosurgical electrode 900. By way of example only, the thickness of electrosurgical electrode 900 may range from approximately 0.45 mm to approximately 0.25 mm. However, alternative thicknesses may be used. In this configuration shown, the plurality of apertures 950 are arranged in an ordered sequence or arrangement (i.e., an array of apertures) within the circular head of working end portion 925. However, alternative aperture arrangements may also be used, such as a plurality of apertures arranged in a non-ordered sequence or arrangement.

[0083] In this exemplary electrosurgical electrode 900, each of the plurality of apertures 950 comprises a circular aperture, with each circular aperture having a generally uniform or constant circumference or radius. However, in alternative circular aperture arrangements, one or more of the circular apertures can have a non-uniform circumference or radius.

[0084] In this example, the electrosurgical electrode 900 further defines a first opening 950a and a second opening 950b. The first opening 950a comprises a semicircular slot passing through the thickness of the electrosurgical electrode 900. By way of example only, the thickness of the electrosurgical electrode 900 may range from approximately 0.45 mm to approximately 0.25 mm. However, alternative thicknesses may be used. In this construction shown, the first opening 950a extends along a length defined by the circular head first portion 940a. In this exemplary electrosurgical electrode 900, the first opening 950a has a generally constant thickness to accommodate the insulating material described herein. However, in alternative constructions, the first opening 950a may have a non-constant thickness.

[0085] Similarly, in the example shown, the second opening 950b comprises a semicircular slot through the thickness of the circular head. In the configuration shown, the second opening 950b extends along a length defined by the second portion 940b of the circular head. In this exemplary electrosurgical electrode 900, the second opening 950b has a generally constant thickness to accommodate the insulating material described herein. However, in alternative configurations, the second opening 950b can have a non-constant thickness.

[0086] First opening 950a, second opening 950b and plurality of openings 950 are configured to receive an insulating material, such as the insulating material shown and described herein in connection with Figures 3-5. For example, the insulating material may be bonded to or wrapped along an exterior surface 970 of electrosurgical electrode 900 such that only a first portion 940a of rim 930, a second portion 940b of rim 930, and a third portion 940c of circular head remain free from the insulating material.

[0087] The one or more apertures 950 provided by the elongated electrosurgical electrode 900 are used to facilitate adhesion of insulating material along the exterior surface 970 of the elongated electrosurgical electrode 900. One intent of the apertures 950 is to allow the insulating material of the first major surface 923 to be joined with the insulating material of the second major surface 927 to create a seamless ring of insulating material that does not tend to lift or delaminate. Alternative geometric aperture configurations, such as triangular, oval, trapezoidal or semicircular aperture configurations, may also be used.

[0088] Figures 15A-15D illustrate an electrosurgical electrode 1500 that can be used with an electrosurgical tool, such as electrosurgical tool 300 shown in Figure 2, according to another exemplary embodiment. Figure 15A illustrates a perspective view of electrosurgical electrode 1500, Figure 15B illustrates a top view of electrosurgical electrode 1500, Figure 15C illustrates a first side view of electrosurgical electrode 1500, and Figure 15D illustrates a second side view of electrosurgical electrode 1500.

[0089] Similar to electrosurgical electrodes 400, 500, 600, 700, 800 described above, electrosurgical electrode 1500 extends axially along a longitudinal axis from a proximal electrode end 1510 to a distal electrode end 1520. Electrosurgical electrode 1500 also includes a first lateral surface 1521 and a second lateral surface 1522 extending from the proximal electrode end 1510 to the distal electrode end 1520. Electrosurgical electrode 1500 further includes a first major surface 1523 and a second major surface 1527 each extending (i) between the proximal electrode end 1510 and the distal electrode end 1520 and (ii) between the first lateral surface 1521 and the second lateral surface 1522. In this configuration, electrosurgical electrode 1500 has a length, width and thickness defined as described above.

[0090] The proximal electrode end 1510 can receive electrical energy from an electrosurgical tool. For example, the electrosurgical electrode 1500 can include an electrically conductive material exposed at the proximal electrode end 1510. This can facilitate electrical coupling between the proximal electrode end 1510 and the electrosurgical instrument for conducting electrical energy from the electrosurgical instrument to the distal electrode end 1520.

[0091] Electrosurgical electrode 1500 includes a working end 1525 configured to cut and coagulate tissue using electrical energy received by the electrosurgical tool. As shown in Figures 15A-15D, electrosurgical electrode 1500 includes a cutting edge 1530A on a first lateral surface 1521 of electrosurgical electrode 1500 and a coagulation edge 1530B on a second lateral surface 1522 opposite first lateral surface 1521 of electrosurgical electrode 1500. Cutting edge 1530A is sharper than coagulation edge 1530B such that when electrical energy is applied to electrosurgical electrode 1500, the density of electrical energy at cutting edge 1530A is greater than the density of electrical energy at coagulation edge 1530B. This allows for the electrosurgical electrode 1500 to provide a cutting edge 1530A that achieves relatively better performance than the coagulation edge 1530B when used during a cutting procedure, and allows for the electrosurgical electrode 1500 to provide a coagulation edge 1530B that achieves relatively better performance than the cutting edge 1530A when used during a coagulation procedure.

[0092] As shown in Figure 15B, the electrosurgical electrode 1500 can further include a body portion 1539 extending between a first lateral surface 1521 and a second lateral surface 1522. As shown in Figures 15C and 15D, the body portion 1539 can define a first major surface 1523 and a second major surface 1527, which are a pair of substantially flat surfaces between the first lateral surface 1521 and the second lateral surface 1522. In other embodiments, the body portion 1539 can have a different shape. In this configuration, the electrosurgical electrode 1500 can be in the form of an electrosurgical blade.

[0093] In an example, the electrosurgical electrode 1500 can include at least one layer of a non-stick material covering an exterior surface of the electrosurgical electrode 1500. For example, the non-stick material can cover at least one of the body portion 1539, the cutting edge 1530A, and the coagulated edge 1530B. Thus, in one embodiment, the non-stick material can cover the body portion 1539, but not the cutting edge 1530A and the coagulated edge 1530B. In another embodiment, the non-stick material can cover the body portion 1539 and the cutting edge 1530A, but not the coagulated edge 1530B. In another embodiment, the non-stick material can cover the body portion 1539 and the coagulated edge 1530B, but not the cutting edge 1530A. In another embodiment, the non-stick material can cover the body portion 1539, the cutting edge 1530A, and the coagulated edge 1530B.

[0094] By way of example, the layer of non-stick material may be formed from a material similar to the insulating material described above, but may be of a thinner thickness to allow electrical energy to be applied to tissue through the portion of the electrosurgical electrode 1500 that is covered by the non-stick coating. For example, the layer of non-stick material may include a polymeric material having a thickness of less than 100 microns. In one example, the polymeric material may include a fluorocarbon material. For example, the fluorocarbon material may include polytetrafluoroethylene (PTFE). Additionally or alternatively, the layer of non-stick material may include a silicone, polyolefin, and / or polyamide having a thickness that permits application of electrical energy to tissue.

[0095] The electrosurgical electrode 1500 may include one or more apertures for coupling a layer of non-stick material to the electrosurgical electrode 1500, or the electrosurgical electrode 1500 may omit apertures. Additionally or alternatively, the layer of non-stick material may be a coating (e.g., a non-stick enamel).

[0096] 15B, the electrosurgical electrode 1500 can include a distal-most end 1526. The distal-most end 1526 can provide a transition section that tapers from a relatively sharp surface of the cutting edge 1530A to a relatively pillow surface of the coagulation edge 1530B. For example, the distal-most end 1526 can provide an edge that tapers inwardly from the coagulation edge 1530B toward the cutting edge 1530A.

[0097] 15A, 15C, and 15D, the electrosurgical electrode 1500 can further include a neck portion 1528 between the proximal and distal electrode portions. The proximal electrode portion can have a cross-sectional size that is larger than the cross-sectional size of the distal electrode portion. This can help accommodate preferential bending of the electrosurgical electrode 1500 at the neck portion 1528 when a force is applied to the distal electrode portion. To transition from the relatively larger size of the proximal electrode portion to the relatively smaller size of the distal electrode portion, the neck portion 1528 can taper inwardly toward a central axis of the electrosurgical electrode 1500 along a direction from the proximal electrode portion to the distal electrode portion.

[0098] 15A-15C, electrosurgical electrode 1500 may additionally or alternatively include one or more apertures and / or one or more layers of insulating material as described above. The apertures and / or layers of insulating material may be of any of the configurations and structures described and shown above in connection with FIGS.

[0099] Figures 16A-16C illustrate an electrosurgical electrode 1600 that can be used with an electrosurgical tool, such as electrosurgical tool 300 shown in Figure 2, according to another exemplary embodiment. Figure 16A illustrates a perspective view of electrosurgical electrode 1600, Figure 16B illustrates a top view of electrosurgical electrode 1600, and Figure 16C illustrates a side view of electrosurgical electrode 1600.

[0100] Similar to electrosurgical electrodes 400, 500, 600, 700, 800, 1500 described above, electrosurgical electrode 1600 extends axially along a longitudinal axis from a proximal electrode end 1610 to a distal electrode end 1620. Electrosurgical electrode 1600 also includes a first lateral surface 1621 and a second lateral surface 1622 extending from the proximal electrode end 1610 to the distal electrode end 1620. Electrosurgical electrode 1600 further includes a first major surface 1623 and a second major surface 1627 each extending (i) between proximal electrode end 1510 and distal electrode end 1620 and (ii) between first lateral surface 1621 and second lateral surface 1622. In this configuration, electrosurgical electrode 1600 has a length, width and thickness defined as described above.

[0101] The proximal electrode end 1610 can receive electrical energy from an electrosurgical tool. For example, the electrosurgical electrode 1600 can include an electrically conductive material exposed at the proximal electrode end 1610. This can facilitate electrical coupling between the proximal electrode end 1610 and the electrosurgical instrument for conducting electrical energy from the electrosurgical instrument to the distal electrode end 1620.

[0102] The electrosurgical electrode 1600 includes a working end 1625 configured to cut tissue using electrical energy received by the electrosurgical tool. In examples, the electrosurgical electrode 1600 includes at least one cutting edge 1630 on a first lateral surface 1621 and / or a second lateral surface 1622 of the electrosurgical electrode 1600. In Figures 16A-16C, the first lateral surface 1621 and the second lateral surface 1622 each include a cutting edge 1630. However, in other examples, the cutting edge 1630 may be provided on only one of the first lateral surface 1621 and the second lateral surface 1622.

[0103] As shown in Figures 16A-16C, each cutting edge 1630 includes a plurality of teeth 1632. As shown in Figure 16B, each tooth 1632 can have a substantially triangular shape such that the base of the tooth 1632 is relatively closer to a central axis of the electrosurgical electrode 1600 and the apex of the tooth 1632 is relatively farther from the central axis than the base. In this configuration, the teeth 1632 can each taper to a relatively small tip point. The teeth 1632 can thus be provided to reduce the surface area of ​​the electrosurgical electrode 1600 at the cutting edge 1630, which can promote concentration of the density of electrical energy applied by the cutting edge 1630 to tissue during a cutting procedure. This can promote improved cutting performance, for example, by reducing charring while cutting tissue.

[0104] As shown in Figure 16B, the electrosurgical electrode 1600 can further include a body portion 1639 extending between the first lateral surface 1621 and the second lateral surface 1622. As shown in Figure 16C, the body portion 1639 can define a first major surface 1623 and a second major surface 1627 in the form of a pair of substantially flat surfaces between the first lateral surface 1621 and the second lateral surface 1622. In other embodiments, the body portion 1639 can have a different shape. In this configuration, the electrosurgical electrode 1600 can be in the form of an electrosurgical blade.

[0105] In some examples, the electrosurgical electrode 1600 can include at least one layer of a non-adhesive material covering an exterior surface of the electrosurgical electrode 1600. For example, the non-adhesive material can cover at least one of the body portion 1639, the first lateral surface 1621, and the second lateral surface 1622. Thus, in one embodiment, the non-adhesive material can cover the body portion 1639, but not the cutting edges 1630 of the first lateral surface 1621 and the second lateral surface 1622. In another embodiment, the non-adhesive material can cover the cutting edges 1630 of the body portion 1639 and the first lateral surface 1621, but not the second lateral surface 1622. In another embodiment, the non-adhesive material can cover the cutting edges 1630 of the body portion 1639 and the second lateral surface 1622, but not the first lateral surface 1621. In another embodiment, the non-stick material can cover the cutting edges 1630 of the body portion 1639 and the first lateral surface 1621 and the second lateral surface 1622 .

[0106] As discussed above, the layer of non-stick material can include a polymeric material. In one example, the polymeric material can include a fluorocarbon material. For example, the fluorocarbon material can include polytetrafluoroethylene (PTFE). The electrosurgical electrode 1600 can include one or more apertures for coupling the layer of non-stick material to the electrosurgical electrode 1600, or the electrosurgical electrode 1600 can omit apertures. Additionally or alternatively, the layer of non-stick material can be a coating (e.g., a non-stick enamel). In other examples, the electrosurgical electrode 1600 can omit the layer of non-stick material.

[0107] 16B, the electrosurgical electrode 1600 can include a distal-most end 1626. In an example, the distal-most end 1626 can omit the plurality of teeth 1632. In another example, the distal-most end 1626 can include the plurality of teeth 1632. In one embodiment in which the distal-most end 1626 includes teeth 1632, the teeth 1632 can continue to extend around the distal-most end 1626 in the same manner as shown for the teeth 1632 along the first lateral surface 1621 and the second lateral surface 1622 (e.g., the size, shape, and / or spacing between the teeth 1632 on the distal-most end 1626 can match the size, shape, and / or spacing of the teeth 1632 on the first lateral surface 1621 and the second lateral surface 1622).

[0108] 16A and 16C, the electrosurgical electrode 1600 can further include a neck portion 1628 between the proximal and distal electrode portions. The proximal electrode portion can have a cross-sectional size that is larger than the cross-sectional size of the distal electrode portion. This can help accommodate preferential bending of the electrosurgical electrode 1600 at the neck portion 1628 when a force is applied to the distal electrode portion. To transition from the relatively larger size of the proximal electrode portion to the relatively smaller size of the distal electrode portion, the neck portion 1628 can taper inwardly toward a central axis of the electrosurgical electrode 1600 along a direction from the proximal electrode portion to the distal electrode portion.

[0109] 17A and 17B illustrate an electrosurgical electrode 1700 that can be used with an electrosurgical tool, such as the electrosurgical tool 300 shown in FIG. 2, according to another exemplary embodiment. The electrosurgical electrode 1700 is substantially similar or identical to the electrosurgical electrode 1600 described above in connection with FIGS. 16A-16C, except that the electrosurgical electrode 1700 includes at least one layer of insulating material 1740 on a portion of an exterior surface 1730 of the electrosurgical electrode 1700. More specifically, the at least one layer of insulating material 1740 covers the body portion 1639, while the teeth 1632 on the first lateral surface 1621 and the second lateral surface 1622 protrude through the at least one layer of insulating material 1740 such that the teeth 1632 are exposed.

[0110] In one embodiment, the insulating material 1740 may be a polymeric heat shrink. In this embodiment, the insulating material 1740 may initially be tubular. The body portion 1639 of the electrosurgical electrode 1700 may be placed into the bore of the insulating material 1740, and then heat may be applied to shrink the insulating material 1740 over the body portion 1639 of the electrosurgical electrode 1700. During the application of heat, the teeth 1632 may pierce and protrude from the insulating material 1740. Thus, the teeth 1632 may be exposed, while the remainder of the body portion 1639 (e.g., including the gaps between the teeth 1632) is covered by the insulating material 1740. In this configuration, the insulating material 1740 may further promote concentration of the density of the electrical energy applied by the cutting edge 1630 to tissue during the cutting procedure. This may promote improved cutting performance, for example, by reducing charring while cutting tissue.

[0111] As described above, the distal-most end 1626 may, in some examples, additionally or alternatively include teeth 1632. In some implementations of such examples, at least one layer of insulating material 1740 may cover the distal-most end 1626 while leaving the teeth 1632 of the distal-most end 1626 exposed in a manner similar to that described above.

[0112] 16A-17B, the teeth 1632 are generally equally spaced relative to one another. However, in other examples, the teeth 1632 can have different distances between adjacent teeth 1632. For example, the distance between a first pair of adjacent teeth 1632 can be different than the distance between a second pair of adjacent teeth 1632.

[0113] 16A-17B, electrosurgical electrodes 1600, 1700 may additionally or alternatively include one or more apertures and / or one or more layers of insulating material as described above. The apertures and / or layers of insulating material may be of any of the configurations and structures described and shown above in connection with FIGS.

[0114] As previously mentioned, the disclosed electrode configurations can be used for both monopolar and bipolar applications. For example, referring now to FIG. 16, a bipolar electrosurgical system 1200 is shown. The bipolar electrosurgical system 1000 includes an RF electrosurgical generator 1100 (also referred to as an electrosurgical unit or ESU). The RF electrosurgical generator 1100 utilizes a first electrosurgical electrode and a second electrosurgical electrode wire 1150 that provide delivery of a radio frequency (RF) current (high frequency current) through tissue 1300 to heat, cut, coagulate, and desiccate the tissue. Such radio frequency (RF) current is a current having a high speed alternating polarity, such as from about 0.1 MHz to about 3 MHz.

[0115] The system 1000 further includes an electrosurgical tool 1400 with two electrosurgical electrodes 1450a, 1450b. As described in detail herein, the exemplary electrosurgical electrodes disclosed herein may be used with such an electrosurgical tool 1400.

[0116] Bipolar electrosurgery often requires less energy to achieve the desired tissue effect, and therefore lower voltages can often be applied. Because bipolar electrosurgery has certain limited capabilities for cutting and coagulating large bleeding areas, bipolar electrosurgery is ideally used for procedures where the tissue can be grasped on both sides by the electrosurgical electrodes 1450a, 1450b. The electrosurgical current in the tissue 1300 is limited to only the tissue 1300 that resides between the two electrosurgical electrodes 1450a and 1450b.

[0117] As used herein, the term "substantially" means that the described property, parameter or value need not be exactly achieved, but rather that deviations or variations, including, for example, tolerance limits, measurement error limits, measurement precision limits, and other factors known to those of ordinary skill in the art, may occur in an amount that does not eliminate the effect that the property was intended to provide.

[0118] Different examples of the systems, devices, and methods disclosed herein include various components, features, and functionality. It is understood that the various examples of the systems, devices, and methods disclosed herein can include any combination of any of the components, features, and functionality of any other examples of the systems, devices, and methods disclosed herein, and all such possibilities are intended to be within the scope of the present disclosure.

[0119] The description of the different advantageous structures has been provided for purposes of illustration and explanation, and is not intended to be exhaustive or limited to the disclosed examples in their forms. Many modifications and variations will be apparent to those skilled in the art. Furthermore, different advantageous examples may demonstrate different advantages over other advantageous examples. The selected example or examples have been chosen and described to explain the principles, practical applications of the examples, and to enable others skilled in the art to understand the present disclosure to various examples with various modifications suitable for the particular use contemplated. The claims as originally filed were as follows: [Claim 1] 1. An electrosurgical electrode for delivering electrical energy, comprising: a proximal electrode end configured to receive electrical energy from an electrosurgical tool; a distal electrode tip; a working end portion between the proximal electrode end and the distal electrode end, the working end portion configured to cut or coagulate tissue using electrical energy received by the proximal electrode end; a first lateral surface; a second lateral surface opposite the first lateral surface; and a first major surface extending between the first lateral surface and the second lateral surface on a first side of the electrosurgical electrode; a second major surface extending between the first lateral surface and the second lateral surface on a second side of the electrosurgical electrode opposite the first side; one or more apertures extending through an entire thickness of the electrosurgical electrode between the first major surface and the second major surface; at least one layer of insulating material bonded to the exterior surface of the working end such that a first portion of the exterior surface is covered by the at least one layer of insulating material and a second portion of the exterior surface is not covered by the at least one layer of insulating material; Equipped with the at least one layer of insulating material is configured to prevent application of electrical current from the first portion of the exterior surface to tissue of a patient; An electrosurgical electrode, wherein the at least one layer of insulating material is bonded to the exterior surface at the one or more openings. [Claim 2] The electrosurgical electrode of claim 1 , wherein the at least one layer of insulating material extends through the one or more openings. [Claim 3] The electrosurgical electrode of claim 1 or claim 2, wherein the at least one layer of insulating material is a continuous loop extending from the first side to the second side through the one or more apertures. [Claim 4] 4. The electrosurgical electrode of claim 1, wherein the one or more openings comprise a slot extending axially along a longitudinal axis between the proximal and distal electrode ends. [Claim 5] 5. The electrosurgical electrode of claim 1, wherein the one or more apertures comprises a plurality of apertures. [Claim 6] The plurality of openings are a first slot extending axially between the proximal electrode end and the distal electrode end; a second slot extending in the axial direction between the proximal electrode end and the distal electrode end; Equipped with The at least one layer of insulating material is (i) extending across the first face between the first slot and the second slot; (ii) extending through the second slot between the first surface and the second surface; (iii) extending across the second surface between the second slot and the first slot; and (iv) extending through the first slot between the second surface and the first surface; 6. An electrosurgical electrode according to claim 5. [Claim 7] the second portion of the exterior surface that is not covered by the at least one layer of insulating material; (i) between the first slot and the first lateral surface; and (ii) between the second slot and the second lateral surface; 7. An electrosurgical electrode according to claim 6. [Claim 8] The electrosurgical electrode of claim 5, wherein the plurality of apertures comprises an array of circular apertures. [Claim 9] 9. The electrosurgical electrode of claim 1, wherein the at least one layer of insulating material comprises a polymeric material. [Claim 10] The electrosurgical electrode of claim 9, wherein the polymeric material comprises polytetrafluoroethylene (PTFE). [Claim 11] 11. An electrosurgical electrode according to any one of claims 1 to 10, wherein the at least one layer of insulating material has a thickness greater than approximately 100 microns. [Claim 12] 12. The electrosurgical electrode of claim 1, wherein the second portion is covered by a layer of material configured to provide for application of an electric current from the second portion of the exterior surface to tissue of a patient. [Claim 13] The electrosurgical electrode of claim 12, wherein the layer of material is a non-stick coating. [Claim 14] 14. An electrosurgical electrode according to claim 12 or claim 13, wherein the layer of material has a thickness less than a thickness of the at least one layer of insulating material. [Claim 15] the first lateral surface having a cutting edge; the second lateral surface having a solidified edge; the cutting edge is sharper than the coagulation edge such that when electrical energy is applied to the electrosurgical electrode, a density of electrical energy at the cutting edge is greater than a density of electrical energy at the coagulation edge; the cutting edge is opposite the coagulated edge; 15. An electrosurgical electrode according to any one of claims 1 to 14. [Claim 16] The electrosurgical electrode of claim 15, wherein the cutting edge has a thickness of about 70 microns to about 200 microns. [Claim 17] 17. An electrosurgical electrode according to any preceding claim, further comprising a plurality of teeth on at least one of the first lateral surface and the second lateral surface. [Claim 18] The electrosurgical electrode of claim 17, wherein a distal-most end of the electrosurgical electrode includes the plurality of tines. [Claim 19] 1. An electrosurgical electrode for delivering electrical energy, comprising: a proximal electrode end configured to receive electrical energy from an electrosurgical tool; a distal electrode tip; a working end portion between the proximal electrode end and the distal electrode end, the working end portion configured to cut or coagulate tissue using electrical energy received by the proximal electrode end; a first lateral surface; a second lateral surface opposite the first lateral surface; and a first surface extending between the first lateral surface and the second lateral surface on a first side of the electrosurgical electrode; a second surface extending between the first lateral surface and the second lateral surface on a second side of the electrosurgical electrode opposite the first side; a plurality of teeth on at least one of the first lateral surface and the second lateral surface; Equipped with An electrosurgical electrode, wherein each of said plurality of tines may be tapered to a respective tip point. [Claim 20] and further comprising at least one layer of insulating material covering a body portion of the electrosurgical electrode. 20. The electrosurgical electrode of claim 19, wherein the tines on the first and second lateral surfaces protrude through the at least one layer of insulating material such that the apex points of the tines are exposed.

Claims

1. 1. An electrosurgical electrode for delivering electrical energy, comprising: a proximal electrode end configured to receive electrical energy from an electrosurgical tool; a distal electrode tip; a working end portion between the proximal electrode end and the distal electrode end, the working end portion configured to cut or coagulate tissue using electrical energy received by the proximal electrode end; a first lateral surface; a second lateral surface opposite the first lateral surface; and a first major surface extending between the first lateral surface and the second lateral surface on a first side of the electrosurgical electrode; a second major surface extending between the first lateral surface and the second lateral surface on a second side of the electrosurgical electrode opposite the first side; a plurality of apertures extending through an entire thickness of the electrosurgical electrode between the first major surface and the second major surface; at least one layer of insulating material bonded to the exterior surface of the working end such that a first portion of the exterior surface is covered by the at least one layer of insulating material and a second portion of the exterior surface is not covered by the at least one layer of insulating material; Equipped with the at least one layer of insulating material does not extend around the entire circumference of the working end portion of the electrosurgical electrode; the at least one layer of insulating material is configured to prevent application of electrical current from the first portion of the exterior surface to tissue of a patient; the at least one layer of insulating material is coupled to the exterior surface and extends through the plurality of openings; The plurality of openings are a first slot extending axially between the proximal electrode end and the distal electrode end; a second slot extending in the axial direction between the proximal electrode end and the distal electrode end; Equipped with The at least one layer of insulating material is (i) extending across the first major surface between the first slot and the second slot; (ii) extending through the second slot between the first major surface and the second major surface; (iii) extending across the second major surface between the second slot and the first slot; and (iv) extending through the first slot between the second major surface and the first major surface; Electrosurgical electrodes.

2. 2. The electrosurgical electrode of claim 1, wherein the second portion of the exterior surface not covered by the at least one layer of insulating material includes portions of each of the first and second major surfaces that are (i) between the first slot and the first lateral surface and (ii) between the second slot and the second lateral surface.

3. The electrosurgical electrode of claim 2 , wherein the plurality of apertures comprises an array of circular apertures.

4. The electrosurgical electrode of any preceding claim, wherein the at least one layer of insulating material comprises a polymeric material.

5. 5. An electrosurgical electrode according to claim 1, wherein the second portion is covered by a layer of material configured to provide for application of an electrical current from the second portion of the exterior surface to tissue of a patient.

6. The electrosurgical electrode of claim 5 , wherein the layer of material has a thickness less than a thickness of the at least one layer of insulating material.

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