US 9,168,084 B2 · Brazed electrosurgical device

Abstract

Disclosed herein is a distal end electrode assembly for use in connection with electrosurgical devices, particularly those adapted for the modification, sculpting, resection, removal, or vaporization of tissue, configured for coagulation, cauterization or hemostasis purposes, or utilized for thermal treatment of normal and tumorous tissues. In the context of the present invention, mechanical fastening means, epoxies and other high-temperature adhesives connecting electrode(s) to insulator(s) are replaced with brazed joints to yield electrosurgical devices capable of safely and reliably operating at high power densities and elevated temperatures without thermal failure of the bonds between the electrode and the insulator. The use of brazed joints further permits the construction of miniaturized, compact electrosurgical devices, of both monopolar and bipolar configurations, having utility in a number of divergent fields, from arthroscopy to otolaryngology to oncology, and applicable to both laparoscopic and open surgery techniques. Thus, active electrodes and electrosurgical devices of the present invention maximize efficiency, safety and reliability while minimizing manufacturing cost and device profile.

Claims35

Dependent claims

An active electrode assembly constructed for connection to an electrosurgical device, said active electrode assembly comprising:

a) an electrode fabricated entirely of a metal material, wherein said electrode has a distal portion comprising an electrically active surface and a proximal portion constructed to connect with the distal end of an electrosurgical device and have an electrical connection to an external power supply such that current flows from said external power supply to said electrically active surface;
and
b) an insulator fabricated entirely of a non-conductive material, said insulator having proximal and distal ends, wherein said insulator is disposed about the distal portion of said metal electrode and is snugly fit against said electrode, such that the distal portion of said electrically active surface extends distally beyond the distal end of said insulator;
wherein said electrode and insulator are permanently affixed directly to each other by means of a brazed joint arising from a braze material disposed between said electrode and said insulator
further wherein the coefficient of thermal expansion of the metal electrode material is more than half (0.5×) and less than twice (2×) the coefficient of thermal expansion of the non-conductive insulator material.

2 more elements

A layered electrode assembly constructed for connection to an electrosurgical device introduced by means of a resectoscope, said assembly comprising:

a) an electrode fabricated entirely of a metal material, wherein said electrode has a planar first surface constructed to connect with the distal end of an electrosurgical device and have an electrical connection to an external power supply, and an opposing non-planarelectrically active second surface such that current flows from said external power supply to said opposing non-planar electrically active second surface;
b) an insulator fabricated entirely of a non-conductive material, said insulator having a planar first surface and an opposing second surface, wherein said planar first surface of said insulator approximates the size and shape of said planar first surface of said metal electrode;
wherein said electrode and insulator are configured to fit together and are permanently affixed directly to each other by means of a brazed joint arising from a braze alloy disposed between said planar first surface of said electrode and said planar first surface of said insulator,
further wherein the coefficient of thermal expansion of the metal electrode material is more than half (0.5×) and less than twice (2×) the coefficient of thermal expansion of the non-conductive insulator material.

1 more element

Dependencies are inferred from the claim text.

Brazed electrosurgical device

Life of this patent

Brazed electrosurgical device

Life of this patent

Abstract

Claims35