Electrosurgical pad apparatus and method of manufacture

A method of making a return electrode for an electrosurgical system comprising the following steps:

• die cutting conductive regions of foil adhered to a carrier;
• peeling off from the carrier a scrap border of foil from the die cut foil about the conductive regions;
• applying a layer of electrically conductive hydrogel over the foil and its carrier, the electrically conductive hydrogel carried on a support, the step of applying a layer forming a sandwich of the combination;
• laminating the sandwich between a pair juxtaposed rollers to adhere them together as a laminate;
• removing the support from the electrically conductive hydrogel of the laminate;
• replacing the support with a liner over the electrically conductive hydrogel;
• removing the carrier from beneath the foil;
• replacing the carrier that has been removed with a film applied over the foil and to the electrically conductive hydrogel thereabove and about;
• and
• cutting the finished sandwich between a pair juxtaposed die cutting rollers while compressing portions of the electrically conductive hydrogel to stretch and reduce the thickness thereof during cutting to cause retraction of the hydrogel.

An apparatus for making a return pad for an electrosurgical system comprising:

• a die cutting roller for die cutting an electrically conductive foil on a backing;
• a take-up for peeling the scrap foil from its backing;
• a rotary press for layering electrically conductive gel together with the die cut foil to form a layered sheet;
• a second die cutting roller having edges for die cutting the layered sheet and,
• a die packing material around at least a portion of the cutting edges sufficient to compress the gel prior to cutting and cause the gel to retract after being cut.