Electrosurgical electrodes, electrosurgical tools, and methods of making electrosurgical electrodes

Abstract

An example electrosurgical electrode includes an elongated body of a conductive material. A distal portion of the elongated body defines a working portion that is configured for at least one of cutting or coagulation of tissue. The working portion includes: (i) a first major surface extending, along the axial direction, on a first side of the working portion, (ii) a second major surface extending, along the axial direction, on a second side of the working portion, (iii) a first outer edge at a first lateral interface between the first major surface and the second major surface, and (iv) a second outer edge at a second lateral interface between the first major surface and the second major surface. The first major surface includes a first concavity and the second major surface includes a second concavity.

Description

Docket No. MBHB 25-0253-WOElectrosurgical Electrodes, Electrosurgical Tools, and Methods of Making Electrosurgical ElectrodesCROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application claims the benefit of U.S. Provisional Application No.63 / 765,262, filed on February728, 2025, the contents of which is hereby incorporated by reference in its entirety.FIELD

[0002] The present disclosure generally relates to electrosurgery and, in particular, to electrosurgical devices, electrosurgical electrodes, and methods of making electrosurgical electrodes.BACKGROUND

[0003] Electrosurgery involves applying a radio frequency (RF) electric current (also referred to as electrosurgical energy) to biological tissue to cut, coagulate, or modify the biological tissue during an electrosurgical procedure. Specifically, an electrosurgical generator generates and provides the electric current to an active electrode, which applies the electric current (and, thus, electrical power) to the tissue. The electric cunent passes through the tissue and returns to the generator via a return electrode (also referred to as a "dispersive electrode”). As the electric cunent passes through the tissue, an impedance of the tissue converts a portion of the electric cunent into thermal energy (e.g., via the principles of resistive heating), which increases a temperature of the tissue and induces modifications to the tissue (e.g., cutting, coagulating, ablating, and / or sealing the tissue). Accordingly, an extent to which the tissue is affected by the electrosurgery is related to the electrical power transmitted from the active electrode to the tissue.BRIEF DESCRIPTION OF THE FIGURES

[0004] The novel features believed characteristic of the illustrative embodiments are set forth in the appended claims. The illustrative embodiments, however, as well as a preferred mode of use, further objectives and descriptions thereof, will best be understood by reference to the follow ing detailed description of an illustrative implementation of the present disclosure when read in conjunction with the accompanying figures, wherein:

[0005] Figure 1 depicts a simplified block diagram of an electrosurgical system, according to an example.

[0006] Figure 2 depicts a perspective view of an electrosurgical device, according to an example.

[0007] Figure 3A depicts a top view of an implementation of an electrosurgical electrode, according to an example.

[0008] Figure 3B depicts a cross-sectional view of the electrosurgical electrode shown in Figure 3A, according to an example.

[0009] Figure 3C depicts a partial perspective view of a portion of the electrosurgical electrode shown in Figure 3A, according to an example.

[0010] Figure 4A depicts the cross-sectional view of the electrosurgical electrode of Figure 3B including a coating of variable thickness, according to an example.

[0011] Figure 4B depicts the cross-sectional view of the electrosurgical electrode of Figure 3B including a coating of an approximately uniform thickness, according to an example.

[0012] Figure 5 A depicts a top view of another implementation of an electrosurgical electrode, according to an example.

[0013] Figure 5B depicts a side view of the electrosurgical electrode shown in Figure 5A, according to an example.

[0014] Figure 5C depicts a cross-sectional view of the electrosurgical electrode shown in Figure 5A, according to an example.

[0015] Figure 5D depicts a partial perspective view of a portion of the electrosurgical electrode shown in Figure 5A, according to an example.

[0016] Figure 6A depicts the cross-sectional view of the electrosurgical electrode of Figure 5C including a coating of variable thickness, according to an example.

[0017] Figure 6B depicts the cross-sectional view of the electrosurgical electrode of Figure 5C including a coating of an approximately uniform thickness, according to an example.

[0018] Figure 7 depicts a thermal profile of a distal region of the electrosurgical electrode shown in Figures 5A-5D, according to an example.

[0019] Figure 8A depicts a top view of an electrosurgical electrode, according to an example.

[0020] Figure 8B depicts a side view of the electrosurgical electrode shown in Figure 8 A, according to the example.

[0021] Figure 8C depicts a first cross-sectional view' of the electrosurgical electrode shown in Figure 8B at an intermediate point along a working portion of the electrosurgical electrode, according to an example.

[0022] Figure 8D depicts a second cross-sectional view of the electrosurgical electrode shown in Figure 8B at a distal point that is distal of the intermediate point, according to the example.

[0023] Figure 9 depicts a flowchart for a method of making an electrosurgical electrode, according to an example.

[0024] Figure 10 depicts a flowchart for a method of making an electrosurgical electrode that can be performed with the method shown in Figure 9, according to an example.

[0025] Figure 11 depicts a flowchart for a method of making an electrosurgical electrode that can be performed with the method shown in Figure 10, according to an example.

[0026] Figure 12 depicts a flowchart for a method of making an electrosurgical electrode that can be performed with the method shown in Figure 10, according to an example.

[0027] Figure 13 depicts a flowchart for a method of operating an electrosurgical device, according to an example.DESCRIPTION

[0028] Disclosed examples will now be described more fully hereinafter 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 should not be construed as 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.

[0029] By the term “approximately” or “substantially” with reference to amounts or measurement values described herein, it is meant that the recited characteristic, parameter, or value need not be achieved exactly, but that deviations or variations, including for example, tolerances, measurement error, measurement accuracy limitations and other factors known to those of skill in the art, may occur in amounts that do not preclude the effect the characteristic was intended to provide.

[0030] As noted above, the extent to which a tissue is affected by electrosurgery is related to the electrosurgical energy transmitted from the active electrode to the tissue. In practice, the electrosurgical energy transmitted from the active electrode to the tissue can be related to, among other things, a physical configuration (e.g., a size and / or a shape) and / or a material composition of the active electrode. Within examples, the present disclosure provides for electrosurgical electrodes having physical configurations and / or material compositions that can improve one or more aspects of an electrosurgery procedure.

[0031] Referring to Figure 1, an electrosurgical system 100 is shown according to an example. As shown in Figure 1, the electrosurgical system 100 includes an electrosurgical generator 110 and an electrosurgical device 112. In general, the electrosurgical generator 110 can generate electrosurgical energy that is suitable for performing electrosurgery on tissue of a patient. For instance, the electrosurgical generator 110 can include a power converter circuit114 that can convert a grid power to electrosurgical energy such as, for example, a radio frequency (RF) output power. As an example, the power converter circuit 114 can include one or more electrical components (e.g., one or more transformers) that can control a voltage, a current, and / or a frequency of the electrosurgical energy;

[0032] Within examples, the electrosurgical generator 110 can include a user interface 116 that can receive one or more inputs from a user and / or provide one or more outputs to the user. As examples, the user interface 116 can include one or more buttons, one or more switches, one or more dials, one or more keypads, one or more touchscreens, one or more display screens, one or more indicator lights, one or more speakers, and / or one or more haptic output devices.

[0033] In an example, the user interface 116 can be operable to select a mode of operation from among a plurality of modes of operation for the electrosurgical generator 110. As examples, the modes of operation can include a cutting mode, a coagulating mode, an ablating mode, and / or a sealing mode. Combinations of these waveforms can also be formed to create blended modes. In one implementation, the modes of operation can correspond to respective waveforms for the electrosurgical energy. As such, in this implementation, the electrosurgical generator 110 can generate the electrosurgical energy with a waveform selected from a plurality of waveforms based, at least in part, on the mode of operation selected using the user interface 116.

[0034] The electrosurgical generator 110 can also include one or more generator sensors 118 that can sense one or more conditions related to the electrosurgical energy and / or the target tissue. As examples, the generator sensor(s) 118 can include one or more current sensors, one or more voltage sensors, one or more temperature sensors, and / or one or more bioimpedance sensors. Within examples, the electrosurgical generator 110 can additionally or alternatively generate the electrosurgical energy with an amount of electrosurgical energy (e.g.,an electrical power) and / or a waveform selected from among the plurality of waveforms based on one or more parameters related to the condition(s) sensed by the generator sensor(s) 118.

[0035] In one example, the electrosurgical energy can have a frequency that is greater than approximately 100 kilohertz (kHz) to reduce (or avoid) stimulating a muscle and / or a nerve near the target tissue. In another example, the electrosurgical energy' can have a frequency that is between approximately 300 kHz and approximately 500 kHz.

[0036] In Figure 1, the electrosurgical generator 110 also includes a connector 120 that can facilitate coupling the electrosurgical generator 110 to the electrosurgical device 112. For example, the electrosurgical device 112 can include a power cord 122 having a plug, which can be coupled to a socket of the connector 120 of the electrosurgical generator 110. In this arrangement, the electrosurgical generator 110 can supply the electrosurgical energy to the electrosurgical device 112 via the coupling between the connector 120 of the electrosurgical generator 110 and the power cord 122 of the electrosurgical device 112.

[0037] The electrosurgical generator 110 can further include a controller 141 that can control operation of the electrosurgical generator 110. Within examples, the controller 141 can be implemented using hardware, software, and / or firmware. For instance, the controller 141 can include one or more processors and a non-transitory computer readable medium (e.g., volatile and / or non-volatile memory) that stores machine language instructions or other executable instructions. The instructions, when executed by the one or more processors, cause the electrosurgical generator 110 to carry' out the various operations described herein. The controller 141, thus, can receive data and store the data in the memory as well. As shown in Figure 1, the controller 141 can be communicatively coupled with the power converter circuit 114, the user interface 116, the generator sensor(s) 118, and / or the connector 120.

[0038] As shown in Figure 1. the electrosurgical device 112 includes a housing 123 having a proximal end and a distal end. and an electrosurgical electrode 128 that can extenddistally of the distal end of the housing 123. The housing 123 can be an elongated structure in and / or on which components of the electrosurgical device 112 can be disposed. In some examples, the housing 123 can be an integral, monolithic structure. In other examples the housing 123 can include a plurality' of discrete structures that are coupled to each other.

[0039] In Figure 1, the housing 123 includes a handle 124 that is configured to facilitate a user gripping and manipulating the electrosurgical device 112 while performing electrosurgery. For example, the handle 124 can have a shape and / or a size that can facilitate a user performing electrosurgery by manipulating the electrosurgical device 112 using a single hand. In one implementation, the handle 124 can have a shape and / or a size that facilitates the user holding the electrosurgical device 112 in a writing utensil gripping manner (e.g., the electrosurgical device 112 can be an electrosurgical pencil). In another implementation, the handle 124 can have a shape and / or a size that facilitates the user holding the electrosurgical device 112 in a pistol grip manner.

[0040] Additionally, as shown in Figure 1 , the housing 123 can include a shaft 126 that extends distally from the handle 124. In some implementations, the shaft 126 can be coupled to the handle 124 in a fixed and non-moveable manner. This may simplify manufacturing and reduce a cost of manufacture by, for instance, simplifying electrical connections that may otherwise need to account for movement of the shaft 126 and the handle 124 relative to each other (e.g., by omitting slip ring electrical contacts and / or sliding electrical contacts). In one example, the handle 124 and the shaft 126 can be formed as a single, monolithic structure such that the shaft 126 and the handle 124 are fixed and non-moveable relative to each other. In another example, the handle 124 and the shaft 126 can be fixedly coupled to each other by a welding coupling, an adhesive coupling, and / or another coupling that prevents movement between the handle 124 and the shaft 126.

[0041] In other implementations, the shaft 126 can be telescopically moveable relative to the handle 124. For example, the shaft 126 can be telescopically moveable in an interior bore defined by the handle 124 to extend the shaft 126 in the distal direction and retract the shaft 126 in a proximal direction relative to the handle 124 (e.g., movable along a longitudinal axis of the electrosurgical device 112). In some examples, the electrosurgical electrode 128 can be coupled to the shaft 126 and, thus, the electrosurgical electrode 128 can move together with the shaft 126 in an axial direction along the longitudinal axis relative to the handle 124. This can provide for adjusting a length of the electrosurgical device 112, which can facilitate performing electrosurgery at a plurality of different depths within tissue (e.g., due to different anatomical shapes and / or sizes of patients) and / or at a plurality of different angles. In other examples, the electrosurgical electrode 128 can be fixedly coupled to the handle 124 such that the shaft 126 is axially movable relative to both the electrosurgical electrode 128 and the handle 124. This can provide for adjusting a length of the electrosurgical electrode 128 that is exposed at the distal end of the shaft 126.

[0042] In some implementations, the electrosurgical electrode 128 can additionally or alternatively be rotatable about an axis of rotation that is parallel to the longitudinal axis of the electrosurgical device 112. In some examples, the electrosurgical electrode 128 can be rotatable relative to the handle 124 and the shaft 126. In other examples, the electrosurgical electrode 128 can be rotationally fixed relative to the shaft 126 such that the shaft 126 and the electrosurgical electrode 128 are rotatable together relative to the handle 124. Rotating the electrosurgical electrode 128 relative to the handle 124 can facilitate adjusting an angle of the electrosurgical electrode 128 relative to one or more user input device(s) 138 of the electrosurgical device 112. In this arrangement, a user can comfortably grip the handle 124 in a position in which their fingers can comfortably operate the user input device(s) 138 while the electrosurgical electrode 128 is set at a rotational position selected from among a plurality ofrotational positions relative to the handle 124 based on, for example, a location, a size, and / or a shape of a surgical site in which the user is operating.

[0043] In one implementation, the electrosurgical electrode 128 can be rotatable by more than 360 degrees relative to the handle 124. This can improve an ease of use by allowing an operator to freely rotate the electrosurgical electrode 128 without limitation. However, in other implementations, the electrosurgical electrode 128 can be rotatable by less than or equal to 360 degrees (e.g., rotatable by 180 degrees, rotatable by 270 degrees, or rotatable by 360 degrees). This may still allow an operator to achieve a desired rotational arrangement, but with the possibility that the operator may rotate in first direction, reach a stop limiting further rotation, and then rotate back in a second direction to achieve the desired rotational arrangement.

[0044] Although it can be beneficial to provide for rotation of the electrosurgical electrode 128 relative to the handle 124 and / or the shaft 126, the electrosurgical electrode 128 can be rotationally fixed relative to the handle 124 and the shaft 126 in some implementations. This may, for example, help to simplify manufacturing and reduce a cost of manufacture by, for instance, simplifying electrical connections that may otherwise need to account for movement of the shaft 126 and the handle 124 relative to each other (e.g., by omitting slip ring electrical contacts and / or sliding electrical contacts).

[0045] Additionally, within examples, the handle 124 and / or the shaft 126 can be constructed from one or more materials that are electrical insulators (e.g., a plastic material). This can facilitate insulating the user from the electrosurgical energy flowing through the electrosurgical device 112 while performing the electrosurgery.

[0046] In Figure 1, the electrosurgical device 112 includes a plurality of electrical components 130 that facilitate supplying the electrosurgical energy, which the electrosurgical device 112 receives from the electrosurgical generator 110, to the electrosurgical electrode 128.As such, the electrical components 130 can provide an electrically conductive bus for supplying the electrosurgical energy' to the electrosurgical electrode 128. In some examples, the electrical components 130 of the electrosurgical device 112 can be electrically coupled to each other in a manner that is suitable to supply electrosurgical energy from the power cord 122 to the electrosurgical electrode 128 while (i) the shaft 126 and / or the electrosurgical electrode 128 telescopically moves relative to the handle 124, and / or (ii) the shaft 126 and / or the electrosurgical electrode 128 rotates relative to the handle 124.

[0047] In some examples, the electrosurgical electrode 128 can be removably coupled to electrical components 130 of the electrosurgical device 112. This can, for example, provide one or more of: (i) interchangeability of electrodes to allow the user to change electrodes quickly based on procedural needs and / or preferences, (ii) replacing an electrosurgical electrode (e.g., due to wear), and / or (iii) reprocessing of electrodes (e.g., to allow for cleaning and / or sterilization). In some implementations, as shown in Figure 1, the electrical components 130 can include an electrode receptacle 132 configured such that the electrosurgical electrode 128 can be coupled to the electrode receptacle 132, decoupled from the electrode receptacle 132, and recoupled to the electrode receptacle 132 (and / or replaced by another electrosurgical electrode 128).

[0048] In other examples, the electrosurgical electrode 128 can be non-removably and fixedly coupled to the electrical components 130. This can help to provide improved electrical contact between the electrical components 130 and the electrosurgical electrode 128, reduce (or minimize) improper coupling of the electrosurgical electrode 128 to the electrical components 130, and / or provide a single-use device. In some implementations, the electrosurgical electrode 128 can be welded to the electrical components 130 of the electrosurgical device 112 (e.g., the electrode receptacle 132 and / or other electrical components 130).

[0049] Additionally, as shown in Figure 1, the electrical components 130 can additionally or alternatively include a printed circuit board 134 (e.g., a flexible printed circuit board) and / or one or more housing conductors 137 (e.g., one or more wires, one or more conductive traces, and / or one or more metal tubes) in some examples. In some implementations, the electrosurgical device 112 can omit the electrode receptacle 132 and instead the electrosurgical electrode 128 can be directly coupled to the housing conductor(s) 137.

[0050] As shown in Figure 1, the electrosurgical device 112 can include one or more user input devices 138 that are operable to control operation of the electrosurgical device 112 and / or the electrosurgical generator 110. For instance, the user input device(s) 138 can be operable to select between the modes of operation of the electrosurgical device 112 and / or the electrosurgical generator 110. In one implementation, the user input device(s) 138 can be configured to select betw een a cutting mode of operation and a coagulation mode of operation. Responsive to actuation of the user input device(s) 138 of the electrosurgical device 112, the electrosurgical device 112 can (i) receive the electrosurgical energy with a level of power and / or a waveform corresponding to the mode of operation selected via the user input device(s) 138 and (ii) supply the electrosurgical energy to the electrosurgical electrode 128.

[0051] Within examples, the user input device(s) 138 can include one or more buttons on an exterior surface of the handle 124. Each button of the user input device(s) 138 can be operable to actuate a respective one of a plurality of switches 136 of the printed circuit board 134. In general, the switches 136 and / or the pnnted circuit board 134 are operable to control a supply of the electrosurgical energy from the electrosurgical generator 110 to the electrosurgical electrode 128. For instance, in one implementation, when each button is operated (e.g., depressed), the respective switch 136 associated with the button can be actuated to cause the printed circuit board 134 to transmit a signal to the electrosurgical generator 110and cause the electrosurgical generator 110 to responsively supply the electrosurgical energy with a level of power and / or a waveform corresponding to a mode of operation associated with the button. In another implementation, operating the button and thereby actuating the respective switch 136 associated with the button can close the switch 136 to complete a circuit to the electrosurgical generator 110 to cause the electrosurgical generator 110 to responsively supply the electrosurgical energy with a level of power and / or a waveform corresponding to a mode of operation associated with the button. In some examples of this implementation, the printed circuit board 134 can be omitted.

[0052] In both example implementations, the electrosurgical energy' supplied by the electrosurgical generator 110 can be supplied from (i) the power cord 122, the printed circuit board 134, and / or the switch(es) 136 to (ii) the electrosurgical electrode 128 by the electrical components 130 (e.g., the electrode receptacle 132 and / or the housing conductor(s) 137). As such, as shown in Figure 1, the printed circuit board 134 can be coupled to the power cord 122, the printed circuit board 134 can be coupled to the housing conductor(s), and the housing conductor(s) can be coupled to the electrosurgical electrode 128. In this arrangement, the housing conductor(s) can conduct the electrosurgical energy to the electrosurgical electrode 128. The switch(es) 136 can be coupled to the printed circuit board 134 in some examples.

[0053] Although the electrosurgical device 112 includes the user input device(s) 138 in Figure 1, the user input device(s) 138 can be separate from the electrosurgical device 112 in another example. For instance, the user input device(s) 138 can additionally or alternatively include one or more foot pedals that are actuatable to control operation of the electrosurgical device 112 as described above. The foot pedal(s) can be communicatively coupled to the electrosurgical generator 110 to provide a signal responsive to actuation of the foot pedal(s).

[0054] As shown in Figure 1. the electrosurgical electrode 128 can include a shank portion 140 and a working portion 142. The shank portion 140 can include a proximal portionof the electrosurgical electrode 128, and the working portion 142 can include a distal portion of the electrosurgical electrode 128. The shank portion 140 can include a conductive material that is configured to electrically couple to the electrical component(s) 130 of the electrosurgical device 112. The working portion 142 can also include the conductive material and is electrically coupled with the conductive material of the shank portion 140 (e.g., as a single, monolithic structure or as electrically coupled discrete components). In this arrangement, the shank portion 140 can receive the electrosurgical energy from the electrical components 130 of the electrosurgical device 112, the shank portion 140 can conduct the electrosurgical energy to the working portion 142, and the working portion 142 can apply the electrosurgical energy to the tissue to perform an electrosurgical operation.

[0055] As described in further detail below, the working portion 142 can include at least a first concavity on a first major surface and a second concavity on a second major surface of the working portion 142. This geometry of the working portion 142 can help to focus and concentrate an electric field density to an area where it is most desired - namely, at a first outer edge and / or a second outer edge of the working portion 142. This effect can be further enhanced by a geometry at the first outer edge and / or the second outer edge, as shown and described with respect to Figures 3A-6B. This concentration of the electric field delivers the electrical energy in a manner which improves the overall user experience.

[0056] In some examples, at least a portion of the working portion 142 the electrosurgical electrode 128 can be covered in a non-stick material (e.g., a material having a relatively low coefficient of friction). As examples, a non-stick material can include at least one material selected from a group consisting of: silicone, siloxane and polytetrafluoroethylene (PTFE). The non-stick material can help to mitigate tissue adhering to the electrosurgical electrode 128. When tissue adheres to an electrosurgical electrode, the tissue may change the effective size and / or shape of the electrode. As such, tissue adherence may impair makingrelatively narrow and precise incisions and, thus, negatively impact a quality and / or a speed of the electrosurgical procedure. However, the non-stick material having a relatively low coefficient of friction can help to mitigate tissue adhering to the electrosurgical electrode 128 as the electrosurgical electrode 128 moves through the target tissue during elcctrosurgery and, thus, improve the quality' and / or speed of the electrosurgical procedure.

[0057] In some examples, at least a portion of the working portion 142 the electrosurgical electrode 128 additionally or alternatively can be covered in an electrical insulation material. This can help to control a distribution of the electrosurgical energy throughout the working portion 142, which can help to achieve a more precise application of the electrosurgical energy to the target tissue. As such, the electrode can beneficially reduce the electrosurgical energy applied to other tissue adjacent to the target tissue, mitigating (or preventing) increasing a temperature of the other tissue and / or cellular damage to the other tissue. Example electrical insulation materials can include, among other material described below, a polymeric material and / or a fluorocarbon material (e g., polytetrafluoroethylene (PTFE)).

[0058] Within examples, the non-stick material and / or the electrical insulator material can be a coating on an exterior surface of the at least the portion of the working portion 142. In some implementations, one or more coatings can be applied to the working portion 142 by one or more processes selected from a group consisting of dip coating, spray coating, electroplating, physical vapor deposition, chemical vapor deposition, and plasma-enhanced vapor deposition.

[0059] Example coating materials can include one or materials selected from a group of materials consisting of titanium nitride, gold, silver, platinum, parylene, diamond-like carbon, silicone, silicone dioxide, polysiloxane, PTFE, tungsten disulfide, ceramic, and enamel.

[0060] Within examples, a viscosity of the coating can be based, at least in part, on the geometry of the working portion 142 (e.g., a quantity and location of concavities of the first and second major surfaces of the working portion 142) to control coating thickness and performance across the width of the blade.

[0061] In some implementations in which the working portion 142 includes an electrical insulator coating, a portion or an entirety of the first outer edge and / or the second outer edge can be masked during the coating process. In other implementations in which the working portion 142 includes an electrical insulator coating, an entirety of the working portion 142 can be coated and then a portion or an entirety' of the first outer edge and / or the second outer edge can be processed after coating for selective coating removal. In other implementations, the working portion 142 of the electrosurgical electrode 128 can be coated and then, responsive to the electrosurgical energy passing through the electrosurgical electrode 128, the electrosurgical energy can degrade the insulative effect of the coating on at least a portion of the working portion 142 (e.g., at the first outer edge and / or the second outer edge).

[0062] In some examples, the coating can be flexible. This can allow a practitioner to bend the working portion 142 to improve a position and / or a shape the electrosurgical electrode 128. In some examples, coatings like ceramic or enamel can be less flexible and prone to cracking when bent. These types of coatings can be paired with regions coated with more flexible coatings or insulators, like heat shrink tubing, or uncoated regions to provide bending regions to reduce the likelihood of cracked coatings while still providing the desired benefits of the coating at the distal end of the electrode. In one example, a distal portion (e.g., a distal 2 millimeter to 5 millimeters) of the working portion 142 of the electrosurgical electrode 128 can be coated with a ceramic and / or enamel coating, and a remainder of the working portion 142 of the electrosurgical electrode 128 can be insulated with heat shrink tubing to provide a bendable region for the electrosurgical electrode 128.

[0063] Referring now to Figure 2, a perspective view of an implementation of the electrosurgical device 112 show n in Figure 1 , according to some examples. As show n in Figure 2, the electrosurgical device 112 includes the handle 124 extending between a proximal end 224A and a distal end 224B, and the shaft 126 extending distally of the distal end 224B of the handle 124. Additionally, in Figure 2, the electrosurgical electrode 128 extends distally of a distal end 226 of the shaft 126. As described above, the electrosurgical electrode 128 can be removably coupled or non-removably coupled to the electrical component(s) 130 (e.g., via a friction-fit coupling, a threaded coupling, a w eld coupling, and / or a solder coupling).

[0064] Figure 2 further depicts a longitudinal axis 244 through a center of the electrosurgical electrode 128. The electrosurgical electrode 128 can be configured according to any of the examples described in further detail below with respect to Figures 3A-6B. Although the example implementation shown in Figure 2 depicts the electrosurgical electrode 128 in connection wdth an electrosurgical pencil, the electrosurgical electrodes 128 described herein can additionally or alternatively be used with other types of electrosurgical devices (e.g., robotic devices and / or an electrosurgical device combined with another type of medical device).

[0065] Figures 3A-3C depict an implementation of the electrosurgical electrode 128, according to an example. Figure 3 A depicts a plan view of the electrosurgical electrode 128, Figure 3B depicts a cross-sectional view of the electrosurgical electrode 128 shown in Figure 3 A, and Figure 3C depicts a partial perspective view of a portion of the electrosurgical electrode 128 shown in Figure 3A. according to the example.

[0066] As shown in Figure 3 A, the electrosurgical electrode 128 includes an elongated body 346 extending in an axial direction from a proximal end 328A to a distal end 328B. The electrosurgical electrode 128 can include a conductive material. For instance, theelectrosurgical electrode 128 can be formed from stainless steel (e.g., grade 300 stainless steel or grade 303 stainless steel).

[0067] Additionally, as shown in Figure 3A, a proximal portion of the elongated body 346 defines the shank portion 140 that is configured to receive electrosurgical energy' from an electrosurgical device 112. In the illustrated example, the shank portion 140 can have a circular cross-sectional shape with a diameter of approximately 2.3 millimeters (i.e., approximately 0.09 inches). In other examples, the shank portion 140 can have a different configuration.

[0068] In Figures 3A-3C, a distal portion of the elongated body 346 defines the working portion 142 that is configured for at least one of cutting or coagulation of tissue by the electrosurgical energy received from the electrosurgical device 112. As shown in Figure 3B-3C, the working portion 142 includes (i) a first major surface 348A extending, along the axial direction, on a first side of the working portion 142, (ii) a second major surface 348B extending, along the axial direction, on a second side of the working portion 142, (iii) a first outer edge 350A at a first lateral interface between the first major surface 348A and the second major surface 348B, and (iv) a second outer edge 350B at a second lateral interface between the first major surface 348 A and the second major surface 348B. The first side of the working portion 142 is opposite the second side of the working portion 142.

[0069] The working portion 142 can also include a distal edge 352 at a distal interface between the first major surface 348 A and the second major surface 348B. As examples, the distal edge 352 can have a square shape or a rounded shape.

[0070] Additionally, as shown in Figures 3B-3C, the first major surface 348A includes a first concavity 354A and the second major surface 348B includes a second concavity 354B between the first outer edge 350A and the second outer edge 350B. In this example, the first concavity’ 354A and the second concavity 354B are at a center portion between the first outeredge 350A and the second outer edge 350B. As shown in Figure 3B, the first concavity 354A and the second concavity 354B define a central waist section 356.

[0071] The first major surface 348 A can define a first shoulder 358A on a first lateral side of the first concavity 354A and a second shoulder 358B on a second lateral side of the first concavity7354A, and the second major surface 348B defines a third shoulder 358C on the first lateral side of the second concavity’ 354B and a fourth shoulder 358D on the second lateral side of the second concavity 354B. As shown in Figure 3B, the first shoulder 358A and the third shoulder 358C define a first lateral bulged section 360A on the first side of the central waist section 356, and the second shoulder 358B and the fourth shoulder 358D define a second lateral bulged section 360B the second side of the central waist section 356.

[0072] The first major surface 348A and the second major surface 348B are tapered inwardly toward each other from the first lateral bulged section 360A to the first outer edge 350A to define a first tapered section 362A, and the first major surface 348A and the second major surface 348B are tapered inwardly toward each other from the second lateral bulged section 360B to the second outer edge 350B to define a second tapered section 362B.

[0073] As shown in Figures 3 A-3B, the working portion 142 can include a thickness T in a dimension extending between the first major surface 348 A and the second major surface 348B, a width W in a dimension extending between the first outer edge 350A and the second outer edge 350B, and a length L in a dimension extending between the proximal end 328A and the distal end 328B. The thickness T, the width W, and the length L are all orthogonal to each other.

[0074] In Figures 3 A-3C, the first outer edge 350A and the second outer edge 350B are substantially planar and extend in respective planes that are parallel to the dimension of the thickness T of the working portion 142. However, in other examples, the first outer edge 350A and the second outer edge 350B can be rounded and / or chamfered.

[0075] In the example shown in Figure 3B, the first major surface 348A and the second major surface 348B are symmetric about an intermediate plane 364 extending through the first outer edge 350A, the second outer edge 350B, and a center of the working portion 142 in a plane shown in Figure 3B (e.g., a center point that is (i) equidistant from the first outer edge 350A and the second outer edge 350B, and (ii) equidistant from the first major surface 348A and the second major surface 348B). As such, a shape of the first major surface 348A and a shape of the second major surface 348B mirror each other. Additionally, in this arrangement, a vertex of the first concavity 354A and a vertex of the second concavity 354B can be aligned with the center of the working portion 142.

[0076] In some examples, the first concavity 354A and the second concavity 354B can each defined by a radius. Further, in some examples, the first concavity 354A and the second concavity 354B can each be defined by a common radius.

[0077] In one example, the working portion 142 can have one or more of the following dimensions: (i) the first concavity 354A and the second concavity 354B can each be defined by a radius of approximately 1.84 millimeters (i.e., approximately 0.07 inches), (ii) the width W of the working portion 142 can be approximately 2.35 millimeters (i.e., approximately 0.93 inches), (iii) the thickness T of the working portion 142 at the first outer edge 350A and the second outer edge 350B can be approximately 0.16 millimeters (i.e., approximately 0.006 inches), and / or (iv) the thickness T of the working portion 142 at the first lateral bulged section 360A and the second lateral bulged section 360B can be approximately 0.50 millimeters (i.e., approximately 0.02 inches).

[0078] As described above, in some examples, at least a portion of the working portion 142 of the electrosurgical electrode 128 can be covered in anon-stick material (e.g., a material having a relatively low coefficient of friction) and / or an electrical insulator material. Figures4A-4B depict the cross-sectional views of the electrosurgical electrode 128 shown in Figure 3B with a coating 466A, 466B, according to example implementations.

[0079] Figure 4A depicts the cross-sectional view of the electrosurgical electrode 128 of Figure 3B including a coating 466A of variable thickness, according to an example. As shown in Figure 4A, the coating 466A covers at least a portion of the w orking portion 142. In this example, the coating 466Ahas a variable thickness on the first major surface 348Aand the second major surface 348B. For instance, as shown in Figure 4A, the coating 466A can be thicker at the central waist section 356 than at the first lateral bulged section 360A and the second lateral bulged section 36B. The thicker portion of the coating 466A at the first concavity 354A and the second concavity 354B of the central waist section 356 relative to other sections of the working portion 142 can help to provide a thermal well that can aid in heat management at the surgical site and surrounding tissue. In some examples, the variable thickness of the coating 466 A can be achieved, for instance, by a dip coating process.

[0080] Figure 4B depicts the cross-sectional view- of the electrosurgical electrode 128 of Figure 3B including a coating 466B of an approximately uniform thickness. As shown in Figure 4B, the coating 466B covers at least a portion of the working portion 142 of the electrosurgical electrode 128. In this example, the coating 466B has an approximately uniform thickness on the first major surface 348A and the second major surface 348B. In this arrangement, the working portion 142 and the coating 466B can define troughs at the first concavity 354A and the second concavity 354B, which reduce tissue contact and drag between the electrosurgical electrode 128 and tissue.

[0081] Figures 5A-5D depict another implementation of the electrosurgical electrode 128, according to another example. Figure 5A depicts a top view of the electrosurgical electrode 128, Figure 5B depicts a side view of the electrosurgical electrode 128 shown in Figure 5 A, Figure 5C depicts a cross-sectional view of the electrosurgical electrode 128 shownin Figures 5A-5B. and Figure 5D depicts a partial perspective view of a portion of the electrosurgical electrode 128 shown in Figures 5A-5B, according to the example.

[0082] As shown in Figures 5A-5B, the electrosurgical electrode 128 includes the elongated body 346 extending in an axial direction from the proximal end 328A to the distal end 328B. The electrosurgical electrode 128 can include the conductive material (e.g., grade 300 stainless steel or grade 303 stainless steel).

[0083] Additionally, as shown in Figures 5A-5B, a proximal portion of the elongated body 346 defines the shank portion 140 that is configured to receive electrosurgical energy from an electrosurgical device 112. In this example, the shank portion 140 can also have a circular cross-sectional shape with a diameter of approximately 2.3 millimeters (i.e., approximately 0.09 inches). In other examples, the shank portion 140 can have a different configuration.

[0084] In Figures 5A-5D, a distal portion of the elongated body 346 defines the w orking portion 142 that is configured for at least one of cutting or coagulation of tissue by the electrosurgical energy received from the electrosurgical device 112. As shown in Figure 5C-5D, the w orking portion 142 includes (i) the first major surface 348A extending, along the axial direction, on the first side of the working portion 142, (ii) the second major surface 348B extending, along the axial direction, on the second side of the working portion 142, (iii) the first outer edge 350A at the first lateral interface between the first major surface 348A and the second major surface 348B, and (iv) the second outer edge 350B at the second lateral interface between the first major surface 348A and the second major surface 348B. The first side of the working portion 142 is opposite the second side of the working portion 142.

[0085] The working portion 142 can also include the distal edge 352 at the distal interface between the first major surface 348A and the second major surface 348B. As examples, the distal edge 352 can have a square shape or a rounded shape.

[0086] As shown in Figure 5C, the first major surface 348A includes a first convexity 568A and the second major surface 348B includes a second convexity 568B at a center portion. In this arrangement, the first convexity' 568A and the second convexity 568B define a central bulged section 570A.

[0087] Additionally, as shown in Figure 5C, the first major surface 348A includes a first concavity' 554A and the second major surface 348B includes a second concavity' 554B between the first outer edge 350A and the second outer edge 350B. In this example, the first concavity' 554A is on a first lateral side of the first convexity' 568A and the second concavity 554B is on a first lateral side of the second convexity' 568B. Additionally, in this example, the first major surface 348 A includes a third concavity' 554C on a second lateral side of the first convexity 568 A, and the second major surface 348B a fourth concavity 554D on a second lateral side of the second convexity 568B. In this arrangement, the first concavity 554A and the second concavity' 554B define a first lateral waist section 572A, and the third concavity 554C and the fourth concavity 554D define a second lateral waist section 572B.

[0088] In Figure 5C, the first major surface 348A can also define a first shoulder 558A on a first lateral side of the first concavity 554A and a second shoulder 558B on a second lateral side of the third concavity 554C, and the second major surface 348B can define a third shoulder 558C on a first lateral side of the second concavity 554B and a fourth shoulder 558D on a second lateral side of the fourth concavity 554D. In this arrangement, the first shoulder 558A and the third shoulder 558C define a first lateral bulged section 570B on a first lateral side of the first lateral waist section 572A, and the second shoulder 558B and the fourth shoulder 558D define a second lateral bulged section 570C on a second lateral side of the second lateral waist section 572B.

[0089] The first maj or surface 348 A and the second maj or surface 348B can be tapered inwardly toward each other from the first lateral bulged section 570B to the first outer edge350A to define a first tapered section 562A, and the first major surface 348A and the second major surface 348B can be tapered inwardly toward each other from the second lateral bulged section 570C to the second outer edge 350B to define a second tapered section 562B.

[0090] As shown in Figures 5A-5C, the working portion 142 can include a thickness T in a dimension extending between the first major surface 348 A and the second major surface 348B, a width W in a dimension extending betw een the first outer edge 350A and the second outer edge 350B, and a length L in a dimension extending between the proximal end 328A and the distal end 328B. The thickness T, the width W, and the length L are all orthogonal to each other.

[0091] In some examples, the central bulged section 570A can have a height H that is greater than a height H of the first lateral bulged section 570B and the second lateral bulged section 570C. This can help to provide the electrosurgical electrode 128 with resistance to bending.

[0092] In Figures 5A-5D, the first outer edge 350A and the second outer edge 350B are rounded. However, in other examples, the first outer edge 350A and / or the second outer edge 350B can be substantially planar and extend in respective planes that are parallel to the dimension of the thickness T of the working portion 142 (e.g., as shown in Figures 3A-3C) and / or include a chamfer.

[0093] In the example shown in Figure 5C, the first major surface 348 A and the second major surface 348B are symmetric about the intermediate plane 364 extending through the first outer edge 350A, the second outer edge 350B, and a center of the working portion 142 in a plane shown in Figure 5C (e.g., a center point that is (i) equidistant from the first outer edge 350A and the second outer edge 350B, and (ii) equidistant from the first major surface 348A and the second major surface 348B). As such, a shape of the first major surface 348A and a shape of the second major surface 348B mirror each other. Additionally, in this arrangement, avertex of the first convexity 568A and a vertex of the second convexity 568B can be aligned with the center of the working portion 142.

[0094] In some examples, the first convexity 568A, the second convexity 568B, the first concavity 554A, the second concavity 554B, the third concavity 554C, the fourth concavity 554D, the first shoulder 558A, the second shoulder 558B, the third shoulder 558C, and / or the fourth shoulder 558D can each defined by a radius. Further, in some examples, the first convexity 568A and the second convexity 568B can each be defined by a common radius. In some examples, the first concavity 554A, the second concavity 554B, the third concavity 554C, and the fourth concavity' 554D can each be defined by a common radius. In some examples, the first shoulder 558A, the second shoulder 558B, the third shoulder 558C, and the fourth shoulder 558D can each be defined by a common radius.

[0095] In one example, the working portion 142 can have one or more of the following dimensions: (i) the first convexity 568A and the second convexity 568B can each be defined by a radius of approximately 1.45 millimeters (i.e., approximately 0.06 inches), (ii) the first concavity 554A, the second concavity 554B, the third concavity 554C, and the fourth concavity 554D can each be defined by a radius of approximately 0.5 millimeters (i.e., approximately 0.02 inches), (iii) the first shoulder 558A, the second shoulder 558B, the third shoulder 558C, and / or the fourth shoulder 558D can each be defined by a radius of approximately 0.27 millimeters (i.e., approximately 0.01 inches), (iv) the first major surface 348 A and the second major surface 348B at the first tapered section 562A and the second tapered section 562B can be defined by a radius of approximately 0.75 millimeters (i.e., approximately 0.03 inches), and / or (v) the first outer edge 350A and the second outer edge 350B can be defined by a radius of approximately 0.05 millimeters (i.e., approximately 0.002 inches). Also, as an example, (vi) the width W of the working portion 142 can be approximately 2.36 millimeters (i.e., approximately 0.09 inches), and / or (vii) the thickness T of the working portion 142 at thecentral bulged section 570A can be approximately 0.50 millimeters (i.e., approximately 0.02 inches).

[0096] As described above, in some examples, at least a portion of the working portion 142 of the electrosurgical electrode 128 can be covered in anon-stick material (e.g., a material having a relatively low coefficient of friction) and / or an electrical insulator material. Figures 6A-6B depict the cross-sectional views of the electrosurgical electrode 128 show n in Figure 5C with a coating 666 A, 666B, according to example implementations.

[0097] Figure 6A depicts the cross-sectional view of the electrosurgical electrode 128 of Figure 5C including a coating 666A of variable thickness, according to an example. As shown in Figure 6A, the coating 666A covers at least a portion of the working portion 142. In this example, the coating 666Ahas a variable thickness on the first major surface 348 A and the second major surface 348B. For instance, as shown in Figure 6A, the coating 466A can be thicker at the first lateral waist section 572A and the second lateral waist section 572B than at the central bulged section 570A. Additionally, as shown in Figure 6A, the coating 466A can be thicker at the first lateral waist section 572A and the second lateral waist section 572B than at the first lateral bulged section 570B and the second lateral bulged section 570C. The thicker portion of the coating 666A at the first concavity 554A, the second concavity 554B, the third concavity 554C, and the fourth concavity 554D of the first lateral waist section 572A and the second lateral waist section 572B relative to other sections of the working portion 142 can help to provide thermal wells that can aid in heat management at the surgical site and surrounding tissue. In some examples, the variable thickness of the coating 666A can be achieved, for instance, by a dip coating process.

[0098] Figure 6B depicts the cross-sectional view of the electrosurgical electrode 128 of Figure 5C including a coating 666B of an approximately uniform thickness. As shown in Figure 6B. the coating 666B covers at least a portion of the working portion 142 of theelectrosurgical electrode 128. In this example, the coating 666B has an approximately uniform thickness on the first major surface 348A and the second major surface 348B. In this arrangement, the working portion 142 and the coating 666B can define troughs at the first concavity 554A, the second concavity 554B, the third concavity 554C, and the fourth concavity 554D, which reduce tissue contact and drag between the electrosurgical electrode 128 and tissue.

[0099] As described above, the physical configurations and / or material compositions of the electrosurgical electrodes 128 shown and described with respect to Figures 3A-6B can help to enhance an electric field density and / or manage heat during an electrosurgical procedure. In some implementations, the electrosurgical electrode 128 can have a constant cross-sectional shape and dimensions over an entire length of the working portion 142 of the electrosurgical electrode 128. In other implementations, the electrosurgical electrode 128 can have a cross-sectional shape and dimensions that vary along the axial direction from a proximal end to a distal. This can help to further enhance thermal performance of the electrosurgical electrode 128.

[0100] For instance, in some implementations in which the electrosurgical electrode 128 has a constant cross-section over the full length of the working portion 142, a temperature at one or more leading comers (i. e. , a comer between the first outer edge 350A and the distal edge 352, or a comer between the second outer edge 350B and the distal edge 352) can heat tissue to a greater extent than more proximal portions of the first outer edge 350A and / or the second outer edge 350B. As an example, Figure 7 depicts a thermal profile of the tissue along the distal edge 352 of the electrosurgical electrode 128 shown in Figures 5A-5D, according to one implementation. As shown in Figure 7. the tissue at the leading comer of the electrosurgical electrode 128 may reach a temperature of approximately 107°C, while tissue at other portions of the electrosurgical electrode 128 reach lower temperatures, such as 91.9°Cand 97.5° C. The thermal profile of Figure 7 is an example of how a uniform cross-section over an entire length of the working portion 142 can result in an uneven distribution of thermal energy.

[0101] To further enhance the performance, the cross-section of the distal portion of the electrosurgical electrode 128 can be varied to achieve a more uniform distribution of thermal energy'. As an example, Figures 8A-8D depict another implementation of the electrosurgical electrode 128, according to another example. Figure 8A depicts a top view of the electrosurgical electrode 128, Figure 8B depicts a side view of the electrosurgical electrode 128 shown in Figure 8A, Figure 8C depicts a first cross-sectional view of the electrosurgical electrode 128 at an intermediate point along the working portion 142 of the electrosurgical electrode 128 shown in Figures 5A-5B, and Figure 8D depicts a second cross-sectional view' of the electrosurgical electrode 128 at a distal point that is distal of the intermediate point and 0.5 millimeters from the distal edge 352 of the electrosurgical electrode 128 shown in Figures 5A-5B, according to the example.

[0102] The electrosurgical electrode 128 shown in Figures 8A-8D is identical to the electrosurgical electrode 128 described above with respect to Figures 5A-5D, except a thickness T (e.g., a diameter) of the first outer edge 350A and a diameter of the second outer edge 350B decreases, along the axial direction towards the distal edge 352, at a distal region of the electrosurgical electrode 128 as shown in Figure 8C and Figure 8D. For instance, the cross-sectional view shown in Figure 8C is proximal of the cross-sectional view shown in Figure 8D. In this example, the first outer edge 350A and the second outer edge 350B are defined by a diameter of 0.050 millimeters at the intermediate point shown in Figure 8C and then decrease to a diameter of 0.020 millimeters at the distal point shown in Figure 8D. As noted above, the distal point can be proximal of the distal edge 352 (e.g., at approximately 0.50 millimeters from the distal edge 352 in this example). By decreasing the diameter of the firstouter edge 350A and the second outer edge 350B, the energy delivery in this specific area can be increased. This results in a more consistent thermal profile and performance across the entire cutting surface of the electrosurgical electrode 128.

[0103] As shown in Figures 8C-8D, the width of the working portion 142 can remain substantially constant over an entirety of the distal region of the working portion 142 (e.g., while the first outer edge 350A and the second outer edge 350B change in diameter at the distal region).

[0104] In some implementations, the first outer edge 350A and the second outer edge 350B can have a varied thickness (e.g., diameter) such that an entirety of the first outer edge 350A and an entirety of the second outer edge 350B heats tissue to between approximately 90 degrees Celsius and approximately 100 degrees Celsius. Maintaining the temperature of tissue within this range ensures the working portion 142 provides sufficient hemostasis while mitigating tissue build-up and / or unwanted thermal spread.

[0105] Although Figures 8A-8D are described as modifications of Figures 5A-5D, the concept of a distal cross-section variation featuring a thinning of the first outer edge 350A and the second outer edge 350B can similarly be implemented in the implementations shown in Figures 3A-4B and Figures 6A-6B.

[0106] Referring now to Figure 9, a flowchart for a process 900 of making an electrosurgical electrode is shown, according to an example. At block 910, the process 900 includes forming an elongated body from a conductive material. The elongated body extends in an axial direction from a proximal end to a distal end. A proximal portion of the elongated body is configured to receive electrosurgical energy from an electrosurgical device. A distal portion of the elongated body defines a working portion that is configured for at least one of cutting or coagulation of tissue by the electrosurgical energy received from the electrosurgical device.

[0107] As show n in Figure 9, forming the elongated body at block 910 can include (i) forming a first major surface extending, along the axial direction, on a first side of the working portion at block 912, and (ii) forming a second major surface extending, along the axial direction, on a second side of the working portion at block 914. The first side of the w orking portion is opposite the second side of the working portion. Forming the elongated body at block 910 can also include (iii) forming a first outer edge at a first lateral interface between the first major surface and the second major surface at block 916, (iv) forming a second outer edge at a second lateral interface between the first major surface and the second major surface at block 918, and (v) forming a distal edge at a distal interface between the first major surface and the second major surface at block 920. The first major surface includes a first concavity and the second major surface includes a second concavity between the first outer edge and the second outer edge.

[0108] Figures 10-12 depict additional aspects of the process 900 according to further examples. As shown in Figure 10, the process 900 can also include covering at least a portion of the working portion with a coating at block 922. As shown in Figure 11, covering the at least the portion of the working portion with the coating at block 922 can include dip coating the w orking portion such that the coating has a variable thickness over on the first maj or surface and the second major surface at block 924. As shown in Figure 12, covering the at least the portion of the working portion with the coating at block 922 can include forming the coating with an approximately uniform thickness over the first major surface and the second major surface at block 926.

[0109] The flowcharts illustrated in Figures 9-12 are examples of a process 900 for making an electrosurgical electrode. In other examples, the process 900 can omit steps, include additional steps, modify the order of steps presented above, and / or include simultaneously performing more than one of the steps presented above.

[0110] Referring now to Figure 13, a flowchart for a process 1300 of operating an electrosurgical device is shown, according to an example. At block 1310, the process 1300 includes coupling an electrosurgical device to an electrosurgical generator. The electrosurgical device includes a housing having a proximal end and a distal end, and an electrosurgical electrode extending distally of the distal end of the housing.

[0111] The electrosurgical electrode includes an elongated body including a conductive material and extending in an axial direction from a proximal end to a distal end. A proximal portion of the elongated body defines a shank portion that is configured to receive electrosurgical energy from an electrosurgical device. A distal portion of the elongated body defines a working portion that is configured for at least one of cutting or coagulation of tissue by the electrosurgical energy received from the electrosurgical device. The working portion includes: (i) a first major surface extending, along the axial direction, on a first side of the working portion, (ii) a second major surface extending, along the axial direction, on a second side of the working portion, wherein the first side of the working portion is opposite the second side of the working portion, (iii) a first outer edge at a first lateral interface between the first major surface and the second major surface, and (iv) a second outer edge at a second lateral interface between the first major surface and the second major surface. The first major surface comprises a first concavity and the second major surface comprises a second concavity between the first outer edge and the second outer edge.

[0112] Additionally, as shown in Figure 13, the process 1300 includes supplying electrosurgical energy from the electrosurgical generator to the electrosurgical electrode at block 1312.

[0113] The flowchart illustrated in Figure 13 is an example of a process 1300 for operating an electrosurgical device. In other examples, the process 1300 can omit steps,include additional steps, modify the order of steps presented above, and / or include simultaneously performing more than one of the steps presented above.

[0114] The description of the different advantageous arrangements has been presented for purposes of illustration and description, and is not intended to be exhaustive or limited to the embodiments in the form disclosed. Many modifications and variations will be apparent to those of ordinary skill in the art. Further, different advantageous embodiments may provide different advantages as compared to other advantageous embodiments. The implementation or implementations selected are chosen and described in order to best explain the principles of the embodiments, the practical application, and to enable others of ordinary' skill in the art to understand the disclosure for various embodiments with various modifications as are suited to the particular use contemplated.

Claims

CLAIMSWHAT IS CLAIMED IS:

1. An electrosurgical electrode, comprising:an elongated body comprising a conductive material and extending in an axial direction from a proximal end to a distal end,wherein a proximal portion of the elongated body defines a shank portion that is configured to receive electrosurgical energy from an electrosurgical device,wherein a distal portion of the elongated body defines a working portion that is configured for at least one of cutting or coagulation of tissue by the electrosurgical energy received from the electrosurgical device,wherein the working portion comprises:a first major surface extending, along the axial direction, on a first side of the working portion,a second major surface extending, along the axial direction, on a second side of the working portion, wherein the first side of the working portion is opposite the second side of the working portion, a first outer edge at a first lateral interface between the first major surface and the second major surface, anda second outer edge at a second lateral interface between the first major surface and the second major surface,wherein the first major surface comprises a first concavity and the second major surface comprises a second concavity between the first outer edge and the second outer edge.

2. The electrosurgical electrode of claim 1 , wherein the first concavity and the second concavity are at a center portion between the first outer edge and the second outer edge, andwherein the first concavity and the second concavity define a central waist section.

3. The electrosurgical electrode of claim 2, wherein the first major surface defines a first shoulder on a first lateral side of the first concavity and a second shoulder on a second lateral side of the first concavity, andwherein the second major surface defines a third shoulder on the first lateral side of the second concavity and a fourth shoulder on the second lateral side of the second concavity, wherein the first shoulder and the third shoulder define a first lateral bulged section on the first side of the central waist section, andwherein the second shoulder and the fourth shoulder define a second lateral bulged section the second side of the central waist section.

4. The electrosurgical electrode of claim 3, wherein the first major surface and the second major surface are tapered inwardly toward each other from the first lateral bulged section to the first outer edge, andwherein the first major surface and the second major surface are tapered inwardly toward each other from the second lateral bulged section to the second outer edge.

5. The electrosurgical electrode of claim 4. wherein the first outer edge and the second outer edge extend between the first major surface and the second major surface are in respective planes that are parallel to a height of the working portion,wherein the height is orthogonal to (i) a width extending between the first outer edge and the second outer edge, and (iii) a length extending between the proximal end and the distal end.

6. The electrosurgical electrode of claim 2, wherein the first concavity and the second concavity are each defined by a common radius.

7. The electrosurgical electrode of any one of claims 3-6, further comprising a coating covering at least a portion of the working portion.wherein the coating has a variable thickness on the first major surface and the second major surface, andwherein the coating is thicker at the central waist section than at the first lateral bulged section and the second lateral bulged section.

8. The electrosurgical electrode of claim 1. wherein the first major surface comprises a first convexity and the second major surface comprises a second convexity at a center portion, wherein the first convexity and the second convexity define a central bulged section.

9. The electrosurgical electrode of claim 8, wherein the first concavity is on a first lateral side of the first convexity and the second concavity is on a first lateral side of the second convexity, andwherein the first major surface comprises a third concavity on a second lateral side of the first convexity, and the second major surface comprises a fourth concavity on a second lateral side of the second convexity, andwherein the first concavity and the second concavity’ define a first lateral waist section, andwherein the third concavity and the fourth concavity define a second lateral waist section.

10. The electrosurgical electrode of claim 9, wherein the first major surface defines a first shoulder on a first lateral side of the first concavity and a second shoulder on a second lateral side of the third concavity , andwherein the second major surface defines a third shoulder on a first lateral side of the second concavity' and a fourth shoulder on a second lateral side of the fourth concavity7, wherein the first shoulder and the third shoulder define a first lateral bulged section on a first lateral side of the first lateral waist section, andwherein the second shoulder and the fourth shoulder define a second lateral bulged section on a second lateral side of the second lateral waist section.

11. The electrosurgical electrode of claim 10, wherein the first major surface and the second major surface are tapered inwardly toward each other from the first lateral bulged section to the first outer edge, andwherein the first major surface and the second major surface are tapered inwardly toward each other from the second lateral bulged section to the second outer edge.

12. The electrosurgical electrode of claim 11, wherein the central bulged section has a height that is greater than a height of the first lateral bulged section and the second lateral bulged section.

13. The electrosurgical electrode of any one of claims 9-12, further comprising a coating covering at least a portion of the working portion.wherein the coating has a variable thickness on the first major surface and the second major surface, andwherein the coating is thicker at the first lateral waist section and the second lateral waist section than at the central bulged section.

14. The electrosurgical electrode of any one of claims 1-6 and 8-12, further comprising a coating covering at least a portion of the working portion,wherein the coating has an approximately uniform thickness on the first major surface and the second major surface.

15. The electrosurgical electrode of any one of claims 1-14, wherein the first major surface and the second major surface are symmetric about a plane extending through the first outer edge, the second outer edge, and a center of the working portion.

16. The electrosurgical electrode of any one of claims 1-15, wherein the working portion further comprises a distal edge at a distal interface between the first major surface and the second major surface, and wherein the distal edge has a rounded shape.

17. The electrosurgical electrode of any one of claims 1-16, wherein a crosssection of the working portion varies along the axial direction.

18. The electrosurgical electrode of claim 17, wherein a diameter of the first outer edge and the second outer edge decreases at a distal region of the working portion.

19. The electrosurgical electrode of claim 18, wherein a width of the working portion remains substantially constant over an entirety of the distal region of the working portion.

20. The electrosurgical electrode of any one of claims 1-16, wherein a cross-sectional shape and dimensions of the working portion are substantially constant over an entire length of the working portion.

21. A method of making an electrosurgical electrode, comprising:forming an elongated body from a conductive material, wherein the elongated body extends in an axial direction from a proximal end to a distal end, wherein a proximal portion of the elongated body is configured to receive electrosurgical energy from an electrosurgical device, wherein a distal portion of the elongated body defines a working portion that is configured for at least one of cutting or coagulation of tissue by the electrosurgical energy7received from the electrosurgical device,wherein forming the elongated body comprises:forming a first major surface extending, along the axial direction, on a first side of the working portion,forming a second major surface extending, along the axial direction, on a second side of the working portion, wherein the first side of the working portion is opposite the second side of the working portion, forming a first outer edge at a first lateral interface between the first major surface and the second major surface,forming a second outer edge at a second lateral interface between the first major surface and the second major surface,forming a distal edge at a distal interface between the first major surface and the second major surface, andwherein the first major surface comprises a first concavity and the second major surface comprises a second concavity between the first outer edge and the second outer edge.

22. The method of claim 21, further comprising covering at least a portion of the working portion with a coating.

23. The method of claim 22, wherein covering the at least the portion of the working portion with the coating comprises dip coating the working portion such that the coating has a variable thickness over on the first major surface and the second major surface.

24. The method of claim 22, wherein covering the at least the portion of the working portion with the coating comprises forming the coating with an approximately uniform thickness over the first major surface and the second major surface.

25. A method of operating an electrosurgical device comprising:coupling an electrosurgical device to an electrosurgical generator, wherein the electrosurgical device comprises a housing having a proximal end and a distal end, and an electrosurgical electrode extending distally of the distal end of the housing,wherein the electrosurgical electrode comprises an elongated body comprising a conductive material and extending in an axial direction from a proximal end to a distal end, wherein a proximal portion of the elongated body defines a shank portion that is configured to receive electrosurgical energy from an electrosurgical device, wherein a distal portion of the elongated body defines a working portion that is configured for at least one of cutting or coagulation of tissue by the electrosurgical energy received from the electrosurgical device, wherein the working portion comprises:a first maj or surface extending, along the axial direction, on a first side of the working portion,a second major surface extending, along the axial direction, on a second side of the working portion, wherein the first side of the working portion is opposite the second side of the working portion, a first outer edge at a first lateral interface between the first major surface and the second major surface, anda second outer edge at a second lateral interface between the first major surface and the second major surface,wherein the first major surface comprises a first concavity and the second major surface comprises a second concavity7between the first outer edge and the second outer edge; andsupplying electrosurgical energy7from the electrosurgical generator to the electrosurgical electrode.

Images