CA2288671C - Gold-plated electrosurgical instrument - Google Patents
Gold-plated electrosurgical instrument Download PDFInfo
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- CA2288671C CA2288671C CA002288671A CA2288671A CA2288671C CA 2288671 C CA2288671 C CA 2288671C CA 002288671 A CA002288671 A CA 002288671A CA 2288671 A CA2288671 A CA 2288671A CA 2288671 C CA2288671 C CA 2288671C
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- electrosurgical instrument
- gold
- intermediate layer
- layer
- instrument
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Classifications
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- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B18/00—Surgical instruments, devices or methods for transferring non-mechanical forms of energy to or from the body
- A61B18/04—Surgical instruments, devices or methods for transferring non-mechanical forms of energy to or from the body by heating
- A61B18/12—Surgical instruments, devices or methods for transferring non-mechanical forms of energy to or from the body by heating by passing a current through the tissue to be heated, e.g. high-frequency current
- A61B18/14—Probes or electrodes therefor
- A61B18/1402—Probes for open surgery
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B17/00—Surgical instruments, devices or methods, e.g. tourniquets
- A61B17/32—Surgical cutting instruments
- A61B17/3209—Incision instruments
- A61B17/3211—Surgical scalpels, knives; Accessories therefor
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B18/00—Surgical instruments, devices or methods for transferring non-mechanical forms of energy to or from the body
- A61B2018/00053—Mechanical features of the instrument of device
- A61B2018/00107—Coatings on the energy applicator
-
- A—HUMAN NECESSITIES
- A61—MEDICAL OR VETERINARY SCIENCE; HYGIENE
- A61B—DIAGNOSIS; SURGERY; IDENTIFICATION
- A61B18/00—Surgical instruments, devices or methods for transferring non-mechanical forms of energy to or from the body
- A61B18/04—Surgical instruments, devices or methods for transferring non-mechanical forms of energy to or from the body by heating
- A61B18/12—Surgical instruments, devices or methods for transferring non-mechanical forms of energy to or from the body by heating by passing a current through the tissue to be heated, e.g. high-frequency current
- A61B18/14—Probes or electrodes therefor
- A61B2018/1405—Electrodes having a specific shape
- A61B2018/1412—Blade
Abstract
An electrosurgical instrument and method for making and using the same, is provided. The electrosurgical instrument includes a stainless steel blade (18) having two major opposed surfaces (20a, 20b) connected by two edge surfaces (22a, 22b) with each surface plated with an intermediate layer (24), comprising a substantially nontoxic metal having a hardness of at least about 130 on a Knoop scale, and an electrical resistivity not exceeding about 15 microhm-cm at 20 degrees Celsius. A non-stick coating (28) is coated on either all of the surfaces of the intermediate layer, or only on the two major opposed surface s, thereby exposing the two edge surfaces of the intermediate layer in the latter case. The non-stick coating prevents tissue from stickin g to the instrument during surgery, while the intermediate metal layer enhances the electrical conductivity of the instrument for more efficient cutting and cauterization of tissue with less power consumption. The combination of an intermediate metal layer with an outer non-stick coati ng eliminates the need to choose between quick and efficient cauterization during surgery, and the prevention of tissue sticking to the instrument.
Description
WO 9$/49954 PCT/US97/11342 GOLD-PLATED EILECTROSURGICAL INSTRUMENT
B~~CKGR.OUND OF THE INVENTION
1. Field of the Invention The present invention relates to the plating of electrosurgical instruments, and, more particularly, to the plating of the steel blade of an electrosurgical instrument with an interme-diate metal layer to enhance; electrical conductivity.
B~~CKGR.OUND OF THE INVENTION
1. Field of the Invention The present invention relates to the plating of electrosurgical instruments, and, more particularly, to the plating of the steel blade of an electrosurgical instrument with an interme-diate metal layer to enhance; electrical conductivity.
2. Description of Related ~~rt Electrosurgical knives or blades currently utilized by surgeons essentially comprise a surgical steel cutting tool, such as a scalpel, and a source of radio-frequency electrical energy for application to the cutting tool. When used in surgery, the surgeon controls the application of radio-frequency electrical energy to the blade to generate heat and cause hemostasis as tis-sue is cut. In this manner, bleeding is minimized during surgery.
While proven effective for controlling bleeding during surgery, electrosurgical knives are rendered less efficient by the stiicking of tissue to the blade such that replacement of the blade is ultimately necessary. A common approach in addressing this problem has been to coat the blade with some type of 'non-stick material to which the cauterized tissue is less likely to adhere. However, the non-stick coating must not prevent the passage of sufficient electrical current from the l;~lade to t:he tissue to achieve hemostasis.
Methods currently employed to achieve reduced sticking to tissue in electrically-conductive electrosurgical blades a:re directed to the configuration of the non-stick coating.
For example, U.S. Patent 1\fo. 4,785,807 discloses an electrosurgical knife in which the thick-ness of the non-stick coating is limited to about 3 mils so that the knife remains conductive.
While the electrical conductivity of a steel blade having a thin non-stick coating is undoubtedly improved over one having a thicker coating, the electrical conductivity remains impeded to a degree. Other methods involve providing small, interspersed conductive openings in a non-stick coating to expose the metallic knife blade to the tissue and ensure the passage of electrical current from the blade to the tissue.
However, these openings typically become coated with charred tissue such that the knives are rendered nonconductive and unusable.
It is therefore desired to provide an electrosurgical knife having both a reduction in sticking and an optimal electrical conductivity. Further, the knife must be readily cleaned and easy to manufacture.
SUMMARY OF THE INVENTION
In accordance with the present invention, an electrosurgical instrument having enhanced electrical conductivity is provided, along with a method for making and using the same. More specifically, the present electrosurgical instrument is provided with an intermediate, low-resistive, non-toxic metal layer to achieve optimal conduction of electrical energy through the instrument to tissue during surgery. An outer non-stick coating is also provided to reduce the sticking of tissue.
In accordance with one aspect of the present invention there is provided an electrosurgical instrument to which electric current can be applied for at least one of cutting and cauterizing tissue, said electrosurgical instrument comprising:
(a) a stainless steel portion capable of conducting said electric current and having two major opposed surfaces connected by two edge surfaces;
(b) an intermediate layer on said major opposed surfaces and said edge surfaces, said intermediate layer comprising a substantially non-toxic metal having a hardness of at least about 130 on a Knoop scale and an electrical resistivity not exceeding about 15 microhm-cm at 20° C.; and (c) a non-stick coating on surfaces of the intermediate layer that overlie said major opposed surfaces, thereby leaving said two edge surfaces with said intermediate layer thereon exposed.
In accordance with another aspect of the present invention there is provided a method for enhancing the electrical conductivity of an electrosurgical instrument used with a source of electrical energy during surgery to perform at least one of cutting and cauterizing tissue, said electrosurgical instrument comprising a stainless steel portion for receiving said electrical energy and having two major opposed surfaces connected by two edge surfaces thereon, said method comprising:
(a) plating on said major opposed and edge surfaces an intermediate layer comprising a substantially non-toxic metal having a hardness of at least about 130 on a Knoop scale and an electrical resistivity not exceeding about 15 microhm-cm at 20°
C; and (b) coating surfaces of said intermediate layer with a non-stick coating that overlie said major opposed surfaces, thereby leaving said two edge surfaces with said intermediate layer thereon exposed;
wherein said electrical energy is conducted from at least one edge surface to cut said tissue and wherein said electrical energy is conducted from at least one edge surface, from at least one major opposed surface, or both, to cauterize said tissue.
The resulting electrosurgical instrument retains the non-stick features of prior art instruments while exhibiting increased electrical conductivity to more efficiently and quickly cauterize tissue. The benefits realized from this increased conductivity are significant. First, the present electrosurgical instrument achieves cleaner cuts in surgery since a lower voltage may be more specifically directed that a higher voltage.
Accordingly, patients sustain less tissue damage given the cleaner cuts.
Second, the reduction in required voltage means that the electrosurgical equipment poses a lesser fire hazard. T hird, lower voltage translates to a reduced chance of burns from the negative ground pad. Fourth, a cost savings is realized in operating the present instrument, since it consumes less power than electrosurgical instruments lacking an intermediate metal layer. Finally, leaving the gold-coated edge surfaces exposed further improves electrical conductivity over edge surfaces coated with the non-stick coating.
While proven effective for controlling bleeding during surgery, electrosurgical knives are rendered less efficient by the stiicking of tissue to the blade such that replacement of the blade is ultimately necessary. A common approach in addressing this problem has been to coat the blade with some type of 'non-stick material to which the cauterized tissue is less likely to adhere. However, the non-stick coating must not prevent the passage of sufficient electrical current from the l;~lade to t:he tissue to achieve hemostasis.
Methods currently employed to achieve reduced sticking to tissue in electrically-conductive electrosurgical blades a:re directed to the configuration of the non-stick coating.
For example, U.S. Patent 1\fo. 4,785,807 discloses an electrosurgical knife in which the thick-ness of the non-stick coating is limited to about 3 mils so that the knife remains conductive.
While the electrical conductivity of a steel blade having a thin non-stick coating is undoubtedly improved over one having a thicker coating, the electrical conductivity remains impeded to a degree. Other methods involve providing small, interspersed conductive openings in a non-stick coating to expose the metallic knife blade to the tissue and ensure the passage of electrical current from the blade to the tissue.
However, these openings typically become coated with charred tissue such that the knives are rendered nonconductive and unusable.
It is therefore desired to provide an electrosurgical knife having both a reduction in sticking and an optimal electrical conductivity. Further, the knife must be readily cleaned and easy to manufacture.
SUMMARY OF THE INVENTION
In accordance with the present invention, an electrosurgical instrument having enhanced electrical conductivity is provided, along with a method for making and using the same. More specifically, the present electrosurgical instrument is provided with an intermediate, low-resistive, non-toxic metal layer to achieve optimal conduction of electrical energy through the instrument to tissue during surgery. An outer non-stick coating is also provided to reduce the sticking of tissue.
In accordance with one aspect of the present invention there is provided an electrosurgical instrument to which electric current can be applied for at least one of cutting and cauterizing tissue, said electrosurgical instrument comprising:
(a) a stainless steel portion capable of conducting said electric current and having two major opposed surfaces connected by two edge surfaces;
(b) an intermediate layer on said major opposed surfaces and said edge surfaces, said intermediate layer comprising a substantially non-toxic metal having a hardness of at least about 130 on a Knoop scale and an electrical resistivity not exceeding about 15 microhm-cm at 20° C.; and (c) a non-stick coating on surfaces of the intermediate layer that overlie said major opposed surfaces, thereby leaving said two edge surfaces with said intermediate layer thereon exposed.
In accordance with another aspect of the present invention there is provided a method for enhancing the electrical conductivity of an electrosurgical instrument used with a source of electrical energy during surgery to perform at least one of cutting and cauterizing tissue, said electrosurgical instrument comprising a stainless steel portion for receiving said electrical energy and having two major opposed surfaces connected by two edge surfaces thereon, said method comprising:
(a) plating on said major opposed and edge surfaces an intermediate layer comprising a substantially non-toxic metal having a hardness of at least about 130 on a Knoop scale and an electrical resistivity not exceeding about 15 microhm-cm at 20°
C; and (b) coating surfaces of said intermediate layer with a non-stick coating that overlie said major opposed surfaces, thereby leaving said two edge surfaces with said intermediate layer thereon exposed;
wherein said electrical energy is conducted from at least one edge surface to cut said tissue and wherein said electrical energy is conducted from at least one edge surface, from at least one major opposed surface, or both, to cauterize said tissue.
The resulting electrosurgical instrument retains the non-stick features of prior art instruments while exhibiting increased electrical conductivity to more efficiently and quickly cauterize tissue. The benefits realized from this increased conductivity are significant. First, the present electrosurgical instrument achieves cleaner cuts in surgery since a lower voltage may be more specifically directed that a higher voltage.
Accordingly, patients sustain less tissue damage given the cleaner cuts.
Second, the reduction in required voltage means that the electrosurgical equipment poses a lesser fire hazard. T hird, lower voltage translates to a reduced chance of burns from the negative ground pad. Fourth, a cost savings is realized in operating the present instrument, since it consumes less power than electrosurgical instruments lacking an intermediate metal layer. Finally, leaving the gold-coated edge surfaces exposed further improves electrical conductivity over edge surfaces coated with the non-stick coating.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the present invention will now be described more fully with reference to the accompanying drawings in which:
S FIG. 1 is a perspective view of a conventional electrosurgical knife;
FIG. 2 is a plan view of an electrosurgical knife having a pointed blade and made in accordance with the principles of the invention; and FIGS. 3a and 3b are enlarged cross-sectional views, taken along lines 3-3 of FIG 2, showing the uncoated surfaces of the blade portion of the knife (FIG.
3a) and the coated surfaces of the blade portion of the knife (FIG. 3b).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is shown a conventional electrosurgical instrument to which is applied electrical energy in the form of a radio-frequency signal for purposes of cauterizing or producing hemostasis simultaneously as tissue is cut during surgery. The knife 10 includes a proximal end 12 which is fitted into a holder to enable a surgeon to more readily hold and guide the knife. A sleeve fitting 14 is positioned around the knife shank 16, which is typically made of insulating rubber, to fa 3a cilitate holding of the knife by the holder. The knife also includes a distal end 18 formed in the shape of a cutting blade 18'.
In the practice of the present invention, the distal end 18 is coated with an in-termediate layer of metal having low contact resistance, sufficient hardness, and sub-stantially no toxicity. In general, the electrical resistance of the metal should not ex-ceed about 15 microhm-cm at 20°C, in comparison to stainless steel type 304, which has an electrical resistance of about 72 microhm-cm. The hardness of the metal should measure at least 130 on a Knoop scale to provide a sufficiently hard layer for use in surgery. Finally, the metal must meet federal guidelines for medical use in this man-ner, hence the requirement that the metal be substantially non-toxic. Three metals are known to meet the requirements for the intermediate layer, namely, gold, rhodium, and palladium, of which gold is preferred, having a hardness ranging from about 130 to 180 on a Knoop scale and an electrical resistivity of about 2.35 at 20°C. However, it should be understood that any metal meeting these three requirements may be em-ployed in the practice of the invention.
As shown in FIG. 3a, the distal end 18 has four surfaces: two major opposed surfaces 20a and 20b, and two side surfaces 22a and 22b, joining the two major sur-faces. The metal layer described below is coated on all four surfaces 20a, 20b, 22a, 22b.
2 o In one embodiment of the present invention, a non-stick coating is then ap-plied to the intermediate layer in the practice of the invention, thereby coating all four surfaces 20a, 20b, 22a, 22b. By coating the stainless steel cutting blade of an electro-surgical instrument in the manner of the invention, the non-stick features of prior ari designs are retained while the electrical conductivity of the instrument is enhanced for 2 5 more efficient, less power-consuming cauterization during surgery.
In another embodiment of the present invention, the non-stick coating is applied only to the two major opposed surfaces 20a, 20b, thereby leaving the two side surfaces 22a, 22b, which are plated with metal, exposed, as shown in FIG. 3b.
Although a specific surgical instrument construction is shown in FIG. 1, it 3 o should be understood that a val7ety of electrosurgical instruments could make use of and benefit from the intermediate metal layer as will be further described hereafter.
For example, the electrosurgical instrument of FIG. 2, which has a pointed cutting blade 18' as opposed to the rounded cutting blade 18' of the electrosurgical instrument in FIG. 1, is also benefited by the practice of the invention. Other examples of electro-surgical instruments benefited in the practice of the invention include those employed in such procedures as laparoscopies. In general, any instrument intended to conduct electrical energy to contacted tissue may be improved as described herein.
With reference to FIG. 3b, the plating of an intermediate metal layer 24 such as gold, rhodium, or palladium onto the stainless steel blade 18 of an electrosurgical instrument may be accomplished by any of the known techniques using commer-cially-available plating baths. Regardless of the choice of metal, the stainless steel sur-faces 20a, 20b, 22a, 22b of the distal end 18 must be prepared for plating. In general, the surfaces 20a, 20b, 22a, 22b are first cleaned to remove grease, oils, oxides, and other contaminants. Then, the surfaces 20a, 20b, 22a, 22b are plated with a thin layer of metal 26, preferably gold, in a atrike process to lay the foundation for the interme-diate metal layer. The intermediate: metal 24 is then plated on top of the strike layer 26 . to a thickness preferably exceeding about 100 micro-inches (0.000254 cm).
Finally, a non-stick coating 28 is dieposited atop the intermediate metal layer 24, on surfaces 20a, 20b only. Each of l:hese steps is described below in further detail. The thick nesses of the coatings shown in FIG. 3b are not to scale.
In the specific process of the invention, the stainless steel portion 18 of the electrosurgical instrument: to be prepared for contact with tissue is first cleaned to re 2 o move grease and oils, typically b:y immersion in a non-etching, hot alkaline cleaner.
An example of such a cleaner is. the electrolytic cleaner Oakite 90 available from Oakite Chemical. Other suitably employed hot alkaline cleaners include commercially available products such as dishwashing compositions; CHEMIZID 740, an aqueous solution of sodium hydroxide and sodium lauryl sulfate available from Allied-Kelite;
2 5 and ALKANOX, an acid-based c;Ieaner having a proprietary composition available from VWR Scientific. In the practice of the invention, Oakite 90 is preferably em-ployed as an aqueous solution ran;;ing in concentration from about 5 to 14 oz./gal. (37 to 105 g/L), with the solution having an applied voltage ranging from about 4 to 6 volts. The Oakite 90 solution bath is preferably operated at a temperature ranging 3 o from about 140° to 160°:F (60° to 71 °C) and a pH ranging from about 13.2 to 13.4.
Immersion time typically ranges from about 1 to 2 minutes. If the part is very oily or greasy, a solvent degrease step nnay be inserted prior to the alkaline cleaning step.
An embodiment of the present invention will now be described more fully with reference to the accompanying drawings in which:
S FIG. 1 is a perspective view of a conventional electrosurgical knife;
FIG. 2 is a plan view of an electrosurgical knife having a pointed blade and made in accordance with the principles of the invention; and FIGS. 3a and 3b are enlarged cross-sectional views, taken along lines 3-3 of FIG 2, showing the uncoated surfaces of the blade portion of the knife (FIG.
3a) and the coated surfaces of the blade portion of the knife (FIG. 3b).
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is shown a conventional electrosurgical instrument to which is applied electrical energy in the form of a radio-frequency signal for purposes of cauterizing or producing hemostasis simultaneously as tissue is cut during surgery. The knife 10 includes a proximal end 12 which is fitted into a holder to enable a surgeon to more readily hold and guide the knife. A sleeve fitting 14 is positioned around the knife shank 16, which is typically made of insulating rubber, to fa 3a cilitate holding of the knife by the holder. The knife also includes a distal end 18 formed in the shape of a cutting blade 18'.
In the practice of the present invention, the distal end 18 is coated with an in-termediate layer of metal having low contact resistance, sufficient hardness, and sub-stantially no toxicity. In general, the electrical resistance of the metal should not ex-ceed about 15 microhm-cm at 20°C, in comparison to stainless steel type 304, which has an electrical resistance of about 72 microhm-cm. The hardness of the metal should measure at least 130 on a Knoop scale to provide a sufficiently hard layer for use in surgery. Finally, the metal must meet federal guidelines for medical use in this man-ner, hence the requirement that the metal be substantially non-toxic. Three metals are known to meet the requirements for the intermediate layer, namely, gold, rhodium, and palladium, of which gold is preferred, having a hardness ranging from about 130 to 180 on a Knoop scale and an electrical resistivity of about 2.35 at 20°C. However, it should be understood that any metal meeting these three requirements may be em-ployed in the practice of the invention.
As shown in FIG. 3a, the distal end 18 has four surfaces: two major opposed surfaces 20a and 20b, and two side surfaces 22a and 22b, joining the two major sur-faces. The metal layer described below is coated on all four surfaces 20a, 20b, 22a, 22b.
2 o In one embodiment of the present invention, a non-stick coating is then ap-plied to the intermediate layer in the practice of the invention, thereby coating all four surfaces 20a, 20b, 22a, 22b. By coating the stainless steel cutting blade of an electro-surgical instrument in the manner of the invention, the non-stick features of prior ari designs are retained while the electrical conductivity of the instrument is enhanced for 2 5 more efficient, less power-consuming cauterization during surgery.
In another embodiment of the present invention, the non-stick coating is applied only to the two major opposed surfaces 20a, 20b, thereby leaving the two side surfaces 22a, 22b, which are plated with metal, exposed, as shown in FIG. 3b.
Although a specific surgical instrument construction is shown in FIG. 1, it 3 o should be understood that a val7ety of electrosurgical instruments could make use of and benefit from the intermediate metal layer as will be further described hereafter.
For example, the electrosurgical instrument of FIG. 2, which has a pointed cutting blade 18' as opposed to the rounded cutting blade 18' of the electrosurgical instrument in FIG. 1, is also benefited by the practice of the invention. Other examples of electro-surgical instruments benefited in the practice of the invention include those employed in such procedures as laparoscopies. In general, any instrument intended to conduct electrical energy to contacted tissue may be improved as described herein.
With reference to FIG. 3b, the plating of an intermediate metal layer 24 such as gold, rhodium, or palladium onto the stainless steel blade 18 of an electrosurgical instrument may be accomplished by any of the known techniques using commer-cially-available plating baths. Regardless of the choice of metal, the stainless steel sur-faces 20a, 20b, 22a, 22b of the distal end 18 must be prepared for plating. In general, the surfaces 20a, 20b, 22a, 22b are first cleaned to remove grease, oils, oxides, and other contaminants. Then, the surfaces 20a, 20b, 22a, 22b are plated with a thin layer of metal 26, preferably gold, in a atrike process to lay the foundation for the interme-diate metal layer. The intermediate: metal 24 is then plated on top of the strike layer 26 . to a thickness preferably exceeding about 100 micro-inches (0.000254 cm).
Finally, a non-stick coating 28 is dieposited atop the intermediate metal layer 24, on surfaces 20a, 20b only. Each of l:hese steps is described below in further detail. The thick nesses of the coatings shown in FIG. 3b are not to scale.
In the specific process of the invention, the stainless steel portion 18 of the electrosurgical instrument: to be prepared for contact with tissue is first cleaned to re 2 o move grease and oils, typically b:y immersion in a non-etching, hot alkaline cleaner.
An example of such a cleaner is. the electrolytic cleaner Oakite 90 available from Oakite Chemical. Other suitably employed hot alkaline cleaners include commercially available products such as dishwashing compositions; CHEMIZID 740, an aqueous solution of sodium hydroxide and sodium lauryl sulfate available from Allied-Kelite;
2 5 and ALKANOX, an acid-based c;Ieaner having a proprietary composition available from VWR Scientific. In the practice of the invention, Oakite 90 is preferably em-ployed as an aqueous solution ran;;ing in concentration from about 5 to 14 oz./gal. (37 to 105 g/L), with the solution having an applied voltage ranging from about 4 to 6 volts. The Oakite 90 solution bath is preferably operated at a temperature ranging 3 o from about 140° to 160°:F (60° to 71 °C) and a pH ranging from about 13.2 to 13.4.
Immersion time typically ranges from about 1 to 2 minutes. If the part is very oily or greasy, a solvent degrease step nnay be inserted prior to the alkaline cleaning step.
Following the alkaline cleaning step, the cleaned parts are rinsed in cold running wa-ter.
The alkaline-cleaned portion of the instrument is then cleaned with an acid to remove remaining oxides and contaminants not removed by the alkaline cleaning step.
Any of the acid etches known for removing oxides may be employed, such as a SO
vol% solution of saturated hydrochloric acid in water. Another suitably employed acid-etch solution comprises ammonium bifluoride double salt, commercially-avail-able from Allied Kelite under the tradename ARP 28. The hydrochloric acid solution is preferably employed in the practice of the invention, with an immersion time of 1 o about 20 to 30 seconds typically being sufficient. Following the acid-etch step, the cleaned parts are again rinsed in cold running water.
The cleaned electrosurgical blade 18 is now ready for plating with the thin metal strike layer 26, such as gold or nickel, which provides a surface to which the intermediate layer 24 may subsequently adhere. The metal strike layer 26 also serves to prevent oxides from reforming after the acid etch step. Preferably, the strike layer 26 comprises gold, which may be achieved by at least two alternate methods in the practice of the invention: ( 1 ) performing an acid gold strike, or (2) performing a nickel strike followed by a gold strike.
In the event an acid gold strike is performed to achieve the gold strike layer 2 0 26, the cleaned electrosurgical blade 18 is immersed in an acid gold strike bath and gold is electroplated onto all four surfaces 20a, 20b, 22a, 22b of the blade.
The re-sulting gald layer 26 preferably ranges in thickness from about 0.000003 to 0.00005 inch (0.0000076 to 0.00013 cm). A thickness of less than about 0.000003 inch may not achieve sufficient adherence of the subsequently-plated intermediate metal layer 2 5 24 thereto, and a thickness of more than about 0.00005 inch may be too brittle.
Any of the known acid gold strike baths may be employed in the practice of the invention, and the bath is typically operated at about room temperature.
Prefera-bly, an acid gold strike bath available from Technic, Inc. (Anaheim, CA) is employed, the acid gold bath having a proprietary composition comprising gold and hydrochloric 3 o acid. In the operation of Technic's acid gold strike bath, gold metal is added to the bath solution as needed to maintain a gold concentration of about 0.25 tr.oz./gal. (2.05 g/L). The Technic acid gold strike bath solution is preferably operated at a tempera-ture ranging from about 80° to 120°F (27° to 49°C) and at a pH of less than about 1.0, as controlled by the presence of hydrochloric acid. In the event a rack method is em-ployed as opposed to a b~irrel method, a current of about 50 to I50 amps/ft2 (538 to 1,614 amps/m2) is impressed on the part, which serves as the cathode. The optimal current density depends upon the oparticular parameters of the plating tank employed, such as its size and material. A typical dwell time of about I to 3 minutes is required to reach the desired range of thickness, with the optimum dwell time depending upon the desired thickness of gold as well as the level of current employed. The optimiza-tion of current density and. dwell time is considered to be a routine endeavor that is well within the capabilities of those having ordinary skill in the art and is not considered to 1 o be undue.
In the event a nickel strike and subsequent gold (non-"acid") strike are per-formed to achieve the thin gold strike layer 26 atop the stainless steel blade 18 of the instrument, both the resulting nickel layer and thin gold layer preferably range in thickness from about 0.000003 to 0.00005 inch (0.0000076 to 0.00013 cm). A
thick-ness of less than about 0.000003 inch may not achieve sufficient adherence of the subsequently-plated intermediate metal layer 24 thereto, and a thickness of more than about 0.00005 inch may be too brittle.
In the practice of the invention, the nickel strike process entails immersing the cleaned electrosurgical blade 18 into a nickel plating bath then electroplating nickel 2 0 onto all four surfaces 20a., 20b, 22a, 22b of the blade in the presence of a nickel an-ode. Any of the known chloride nickel strike baths may be employed in the practice of the invention, and the bath is typically operated at about room temperature.
Prefera-bly, the nickel plating ba~:h comprises an aqueous solution of nickel chloride and hy-drochloric acid, with the nickel chloride ranging in concentration from about 26 to 48 oz./gal. (210 to 359 g/L) and the hydrochloric acid ranging in concentration from about 20 to 70 oz./gal. ( 1 50 to 524 g/L). Preferably, nickel chips serve as the anode. A
current of about 15 to 3~D amps/ia2 (161 to 323 amps/m') is impressed on the pare, which serves as the cathode. The optimal current density depends upon the particular parameters of the plating tank employed, such as its size and material. A
typical dwell 3 0 time of about 2 to 3 minutes is required to reach the desired range of thickness, with the optimum dwell time depending upon the desired thickness of nickel as well as the level of current employed. The optimization of current density and dwell time is con-sidered to be a routine endeavor that is well within the capabilities of those having ordi-t nary skill in the art and is not considered to be undue.
If a nickel strike layer has been deposited, a gold strike process (as opposed to an acid gold strike process) is then performed to deposit a thin gold strike layer as a precursor to the subsequent electroplating of an intermediate metal layer. In the prac tice of the invention, the gold strike process entails immersing the cleaned electrosur-gical blade 18 into a gold plating bath and then electroplating gold onto all four sur-faces 20a, 20b, 22a, 22b of the blade. Any of the known gold strike baths capable of depositing gold atop nickel may be employed in the practice of the invention.
Prefera-l0 bly, the gold plating bath is an aqueous solution comprising gold metal, potassium cyanide, and dipotassium phosphate, with the gold metal ranging in concentration from 0.056 to 0.20 tr.oz./gal (0.46 to 1.64 g/L), potassium cyanide ranging in concen-tration from about 0.18 to 0.31 oz./gal. (1.35 to 2.32 g/L), and dipotassium phosphate ranging in concentration from about 1.75 to 2.5 oz./gal. ( 13.1 to 18.7 g/L).
Also pref erably, gold metal is simply added to the solution as necessary throughout the plating process, as opposed to employing a gold metal anode. A current of about 2 to 4 amps/ft~ (21.5 to 43.1 amps/m2) is impressed on the part, which serves as the cathode.
The gold strike bath is preferably operated at a temperature ranging from about 140°
to 150°F (60° to 66°C) and a pH ranging from about 9.5 to 12Ø Typically, a dwell 2 0 time of about 5 to 10 seconds is required to reach the desired range of thickness, with the optimum dwell time depending upon the desired thickness of gold as well as the level of current employed. The optimization of current density and dwell time is con-sidered to be a routine endeavor that is well within the capabilities of those having ordi-nary skill in the art and is not considered to constitute undue experimentation.
2 5 Addition agents such as wetters and brighteners may be included in the acid strike, nickel strike, or gold strike baths to enhance the strike characteristics. The composition and concentration of such addition agents are well-known in the art and hence do not form a part of this invention. At the conclusion of the deposition of a thin strike layer 26, the part is rinsed in cold running water in preparation for electro 3 0 plating an intermediate metal layer.
Once a thin strike layer 26 is in place, the intermediate metal layer 24 may then be electroplated to a preferred thickness of at least about 100 micro-inches (0.000254 cm). A thickness of less than about 100 micro-inches would likely not be sufficiently hard. Regardless of vvhether gold, rhodium, or palladium is chosen to serve as the intermediate layer 24, there are known techniques and electroplating baths to electroplate such a layer. Any of such known techniques may be employed in the practice of the invention to provide an intermediate metal layer 24 atop the thin strike layer 26. Since the intermediate metal layer 24 preferably comprises gold, further de-tail is provided below regarding the process of electroplating gold onto the strike layer 26. It is expected that the; process. for electroplating rhodium or palladium onto the strike layer 26 would be a~ialogous.
To electroplate an intermediate layer 24 of gold atop the strike layer 26, the portion 18 of the instrument to bc: plated is immersed in a gold electroplating bath, preferably according to a rack method. Any of the known gold electroplating baths may be employed in the practice o:f the invention. Preferably, Techni Gold -25, a pro-prietary non-cyanide gold plating bath commercially-available from Technic, Inc., is employed in the practice o~f the invention to achieve a gold layer 24 having a hardness ranging from about 130 t~o 180 on a Knoop scale. Rather than employ a gold metal anode, gold metal is prei:erably added to the solution as necessary throughout the plating process. A current of about 3 to 5 amps/ft2 (32.3 to 53.8 amps/mz) is impressed on the part, which serves as the cathode. Typically, a dwell time of about 12 minutes is required to plate about 100 micro-inch of gold using the Techni-Gold 25 bath in a 2 0 rack method. The optimization of current density and dwell time is considered to be a routine endeavor that is wc;ll within the capabilities of those having ordinary skill in the art and is not considered tn be undue. The Techni Gold - 25 gold plating bath is pref=
erably operated at a temperature ranging from about 120° to 140°F (49° to 60°C) and a pH ranging from about 8.8 to 10.7, with the pH being preferably adjusted using a 2 5 20% solution of sodium hydroxide.
Addition agents such as wetters and brighteners may also be included in the gold electroplating bath to enhance the plating characteristics. For example, a bright ener permits use of higher current densities to achieve a harder deposit. The composi tion and concentration of such adalition agents are well-known in the art and hence do 3 0 not form a part of this invention.
Following the ele~~troplating of the intermediate metal layer 24, a hot water rinse may be used if needed to remove contaminants. Finally, the electrosurgical in-strument may be dried, preferably with compressed air, in preparation for the applica-tion of a non-stick surface.
In the first embodiment of the present invention, that portion of the electrosur gical instrument (surfaces 20a, 20b, 22a, 22b} that has been plated with an intermedi ate metal layer is then coated with an intermediate metal layer 24 is then coated with a non-stick material 28 comprising a fluoropolymer material, with the fluoropolymer material preferably preceded by a coating of liquefied primer material (not shown).
Any of the primer materials commonly used as precursors to fluoropolymer material for electrosurgical instruments may be employed in the practice of the invention, such as primer materials commercially available from Whitford Corp. and DuPont. For aesthetic purposes, it is preferable that the primer coating be clear such that the un-derlying metal is visible. Preferably, the primer material is sprayed onto the metal-plated major surfaces 20a, 20b of the blade 18 using, for example, an airbrush tech-nique.
In the second embodiment of the present invention, only the major surfaces 20a, 20b of the portion 18 of the electrosurgical instrument that have been plated with an intermediate metal layer 24 are then coated with the non-stick material 28, as shown in FIG. 3b.
After the primer material is dried, the blade 18 is placed in a kiln oven for less 2 0 than about 5 minutes (preferably about 1 minute) at a temperature ranging from about 450° to 850°F (232° to 455°C). The optimum temperature within this range depends upon the particular primer material employed. After removal from the oven, the blade 18 and primer material are allowed to cool to room temperature.
Finally, a coat 28 of fluoropolymer material is applied to the primer material.
2 5 Suitably employed fluoropolymer materials include, but are not limited to poly-tetrafluoroethylene (PTFE) and fluorinated ethylenepropylene resin (FEP).
Preferably, the fluoropolymer material is sprayed onto the primer material, or in the absence of primer material, directly onto the intermediate metal layer 24. An air brush may be employed to effect a spray. After applying the fluoropolymer material, the blade 18 3 o and material are preferably allowed to dry for about one hour at room temperature.
The blade 18 is then placed in a preheated oven for less than about 5 minutes (preferably about 1 minute) at a temperature ranging from about 450° to 850°F (232°
to 455°C). The optimum temperature within this range depends upon the particular fluoropolymer material emiployed. .After removal from the oven, the coated blade 18 is allowed to cool to room temperature. Upon cooling, the blade 18 may be polished to a high sheen using a soft cotton cloth. to remove dirt and debris.
The total thickness of the non-stick coating 28 is preferably about 0.002 inch (0.005 cm). The non-stick coating :Z8 as defined herein includes both the primer mate-rial and the fluoropolymer material. Thus, if a coat of fluoropolymer material is em-ployed alone, it preferably has a thickness of about 0.002 inch.
Alternatively, if both a primer coat and fluoropolymer coat: are employed as the non-stick coating 28, the non-stick coating preferably has a total thickness of about 0.002 inch. If the non-stick 1 o coating 28 is too thick, it nnay be too soft and might be susceptible to cracking. On the other hand, if the non-stick; coating 28 is too thin, incomplete coverage of the interme-diate gold layer may result.
In the second embodiment of the present invention, the edges 22a, 22b may be protected during the deposition of the primer coat and the non-stick material 28 by use of a conventional mask on the edge, only, which is then removed following the depo sitions to expose the metal-coated edges. Alternatively, the entire portion 18 may be coated with the primer coat and the non-stick material 28 and the edges 22a, 22b ex-posed subsequent to the coatings by use of an abrasive or sharp-edged instrument to remove the coatings from the edge:. only.
2 0 The electrosurgical. instrument 10 manufactured and used in accordance with the present invention eliminates the need to choose between quick and efficient cau-terization during surgery and the prevention of tissue sticking to the instrument.
Rather, the present instrument retains the non-sticking capabilities of the prior art while enhancing the electrical conductivity of the instrument with gold plating. As 2 5 such, the length of time required for cauterization is minimized as is the amount of power necessary to achieve cauteri:aation. Furthermore, the process by which the pres-ent electrosurgical instrument is manufactured is relatively simple and easily auto-mated.
As indicated above; and as illustrated in FIG. 3b, the metal-coated edges 22a, 3 0 22b are not coated by the fluoropolymer or by the primer, and hence are exposed. Be cause the edges 22a, 22b are not coated by the fluoropolymer or by the primer, and thus are exposed, better c;lectrical conductivity is obtained to cut flesh along these edges and to cauterize flesh, yet the major surfaces 20a, 20b, being coated with the WO 98/49954 PCT/tJS97/11342 fluoropolymer coating, allow passage of the blade 18 through flesh without sticking, permitting easier cleaning of the blade and reducing surgical time. While cutting is not done by the major surfaces 20a, 20b, cauterizing may be done by these major sur-faces.
EXAMPLES
A comparison has been made between four electrosurgical instruments to il-lustrate the advantages realized in the practice of the invention. The stainless steel blades of the four electrosurgical instrurrlents were prepared for testing as follows:
~ Electrosurgical instrument "A": The stainless steel blade remained uncoated.
~ Electrosurgical instrument "B": The stainless steel blade was coated with TeflonTM in accordance with the teachings of U.S. Pat-ent No. 4,785,807.
~ Electrosurgical instrument "C": The stainless steel blade was se-quentially coated with a thin acid gold strike layer, a layer of gold having a thickness of about 100 micro-inch, a primer coat, and a polytetrafluoroethylene coating, all in accordance with the teach-2 0 ings of the first embodiment herein.
~ Electrosurgical instrument "D": The stainless steel blade was coated as in the case of the Electrosurgical instrument "C", except that the edges were free of the primer coat and the polytetrafluoro-ethylene coating, in accordance with the teachings of the second 2 5 embodiment of the present invention.
The four instruments were each employed in surgical procedures. The quantity of electrical energy made available to the instruments for purposes of inducing hemo-stasis during surgery was controlled by a power dial having an uncalibrated range from 1 to 10. Thus, while the particular amount of watts employed for each instrument 3 0 is unknown, the power dial setting indicates in relative terms the amount of electrical energy required such that a comparison between instruments may be made.
Observa-tions regarding power settings, tissue sticking, and tissue damage follow for each in-strument.
Electrasur~l instntment "A": This instrument required power settings ranging from about 3 to '7 to achieve hemostasis during surgery. Without a non-stick coating of any sort, this instrument sustained extensive tissue sticking such that the surgeon had to frequently clean the instrument during surgery, thus increasing the time of surgery.
Electrosurgical instrument "B": This instrument required power settings ranging from about 5 to 10 to achieve hemostasis, which is considerably more wattage than that required for instntment "A". As a result of the increased wattage, more tissue damage was sustained compared 'with instrument "A". Further, the increased voltage elevated the fire hazard associated with employing an electrosurgical instrument. On the other hand, less tissue: adhered to the TeflonTM-coated blade than the bare stainless steel blade of instrument "A", and any tissue that perchance did adhere to blade "B"
was readily cleaned. Thus, less surgical time was expended cleaning instrument "B"
than instrument "A".
Electrosur ic>' al instrument "C": This instrument required power settings ranging from about 3 to E>, which was a considerable improvement over the TeflonTM_ coated instrument "B" and even a slight improvement over the bare stainless steel 2 0 blade of instrument "A". The gold interlayer provided a more concentrated power source for hemostasis sc~ that cuts were cleaner. Accordingly, the amount of tissue damage observed for instrument "C" was comparable to that of instrument "A"
and much less than that of instrument "B". Further, like instrument "B", this instrument experienced little tissue adherence given its non-stick coating, and any tissue that did 2 5 stick was readily cleaned.
Electrosurgical imstrumer~t "D": This instrument required power settings ranging from about 1 to ~E, which was a noticeable improvement over even Electrosur-gical instrument "C". The lower power, which was concentrated to the edges, resulted in a better and smoother cut, with less damage to the tissue. There were fewer fumes 3 0 due to the lower setting, thereby posing less of a fire hazard.
In sum, it has been illustrated that an electrosurgical instrument made in ac-cordance with the preser.~t invention combines the advantages of prior art instruments while eliminating their significant disadvantages. More specifically, electrosurgical instruments "C" and "D" both conducted electrical energy better than the bare stain-less steel blade of electrosurgical instrument "A" so that lower power was possible to achieve hemostasis during surgery, thereby inflicting less tissue damage and posing a lesser fire hazard. Further, electrosurgical instruments "C" and "D" also exhibited a lesser tissue adherence on par with the TeflonTM-coated blade of instrument "B".
Essentially, it has been demonstrated that an electrosurgical instrument made in accordance with the present invention enables a surgeon to take advantage of a non-stick coating without subjecting patients to increased tissue damage deriving from the use of a diffused power source to achieve hemostasis.
l0 Thus, there has been disclosed an electrosurgical instrument having an inter-mediate metal layer topped by a non-stick coating. A method of enhancing the electri-cal conductivity of an electrosurgical instrument is also disclosed, along with a method of using the resulting electrosurgical instrument. It will be appreciated by those skilled in the art that various changes and modifications of an obvious nature may be made, and all such changes and modifications are considered to fall within the scope of the invention, as defined by the appended claims.
The alkaline-cleaned portion of the instrument is then cleaned with an acid to remove remaining oxides and contaminants not removed by the alkaline cleaning step.
Any of the acid etches known for removing oxides may be employed, such as a SO
vol% solution of saturated hydrochloric acid in water. Another suitably employed acid-etch solution comprises ammonium bifluoride double salt, commercially-avail-able from Allied Kelite under the tradename ARP 28. The hydrochloric acid solution is preferably employed in the practice of the invention, with an immersion time of 1 o about 20 to 30 seconds typically being sufficient. Following the acid-etch step, the cleaned parts are again rinsed in cold running water.
The cleaned electrosurgical blade 18 is now ready for plating with the thin metal strike layer 26, such as gold or nickel, which provides a surface to which the intermediate layer 24 may subsequently adhere. The metal strike layer 26 also serves to prevent oxides from reforming after the acid etch step. Preferably, the strike layer 26 comprises gold, which may be achieved by at least two alternate methods in the practice of the invention: ( 1 ) performing an acid gold strike, or (2) performing a nickel strike followed by a gold strike.
In the event an acid gold strike is performed to achieve the gold strike layer 2 0 26, the cleaned electrosurgical blade 18 is immersed in an acid gold strike bath and gold is electroplated onto all four surfaces 20a, 20b, 22a, 22b of the blade.
The re-sulting gald layer 26 preferably ranges in thickness from about 0.000003 to 0.00005 inch (0.0000076 to 0.00013 cm). A thickness of less than about 0.000003 inch may not achieve sufficient adherence of the subsequently-plated intermediate metal layer 2 5 24 thereto, and a thickness of more than about 0.00005 inch may be too brittle.
Any of the known acid gold strike baths may be employed in the practice of the invention, and the bath is typically operated at about room temperature.
Prefera-bly, an acid gold strike bath available from Technic, Inc. (Anaheim, CA) is employed, the acid gold bath having a proprietary composition comprising gold and hydrochloric 3 o acid. In the operation of Technic's acid gold strike bath, gold metal is added to the bath solution as needed to maintain a gold concentration of about 0.25 tr.oz./gal. (2.05 g/L). The Technic acid gold strike bath solution is preferably operated at a tempera-ture ranging from about 80° to 120°F (27° to 49°C) and at a pH of less than about 1.0, as controlled by the presence of hydrochloric acid. In the event a rack method is em-ployed as opposed to a b~irrel method, a current of about 50 to I50 amps/ft2 (538 to 1,614 amps/m2) is impressed on the part, which serves as the cathode. The optimal current density depends upon the oparticular parameters of the plating tank employed, such as its size and material. A typical dwell time of about I to 3 minutes is required to reach the desired range of thickness, with the optimum dwell time depending upon the desired thickness of gold as well as the level of current employed. The optimiza-tion of current density and. dwell time is considered to be a routine endeavor that is well within the capabilities of those having ordinary skill in the art and is not considered to 1 o be undue.
In the event a nickel strike and subsequent gold (non-"acid") strike are per-formed to achieve the thin gold strike layer 26 atop the stainless steel blade 18 of the instrument, both the resulting nickel layer and thin gold layer preferably range in thickness from about 0.000003 to 0.00005 inch (0.0000076 to 0.00013 cm). A
thick-ness of less than about 0.000003 inch may not achieve sufficient adherence of the subsequently-plated intermediate metal layer 24 thereto, and a thickness of more than about 0.00005 inch may be too brittle.
In the practice of the invention, the nickel strike process entails immersing the cleaned electrosurgical blade 18 into a nickel plating bath then electroplating nickel 2 0 onto all four surfaces 20a., 20b, 22a, 22b of the blade in the presence of a nickel an-ode. Any of the known chloride nickel strike baths may be employed in the practice of the invention, and the bath is typically operated at about room temperature.
Prefera-bly, the nickel plating ba~:h comprises an aqueous solution of nickel chloride and hy-drochloric acid, with the nickel chloride ranging in concentration from about 26 to 48 oz./gal. (210 to 359 g/L) and the hydrochloric acid ranging in concentration from about 20 to 70 oz./gal. ( 1 50 to 524 g/L). Preferably, nickel chips serve as the anode. A
current of about 15 to 3~D amps/ia2 (161 to 323 amps/m') is impressed on the pare, which serves as the cathode. The optimal current density depends upon the particular parameters of the plating tank employed, such as its size and material. A
typical dwell 3 0 time of about 2 to 3 minutes is required to reach the desired range of thickness, with the optimum dwell time depending upon the desired thickness of nickel as well as the level of current employed. The optimization of current density and dwell time is con-sidered to be a routine endeavor that is well within the capabilities of those having ordi-t nary skill in the art and is not considered to be undue.
If a nickel strike layer has been deposited, a gold strike process (as opposed to an acid gold strike process) is then performed to deposit a thin gold strike layer as a precursor to the subsequent electroplating of an intermediate metal layer. In the prac tice of the invention, the gold strike process entails immersing the cleaned electrosur-gical blade 18 into a gold plating bath and then electroplating gold onto all four sur-faces 20a, 20b, 22a, 22b of the blade. Any of the known gold strike baths capable of depositing gold atop nickel may be employed in the practice of the invention.
Prefera-l0 bly, the gold plating bath is an aqueous solution comprising gold metal, potassium cyanide, and dipotassium phosphate, with the gold metal ranging in concentration from 0.056 to 0.20 tr.oz./gal (0.46 to 1.64 g/L), potassium cyanide ranging in concen-tration from about 0.18 to 0.31 oz./gal. (1.35 to 2.32 g/L), and dipotassium phosphate ranging in concentration from about 1.75 to 2.5 oz./gal. ( 13.1 to 18.7 g/L).
Also pref erably, gold metal is simply added to the solution as necessary throughout the plating process, as opposed to employing a gold metal anode. A current of about 2 to 4 amps/ft~ (21.5 to 43.1 amps/m2) is impressed on the part, which serves as the cathode.
The gold strike bath is preferably operated at a temperature ranging from about 140°
to 150°F (60° to 66°C) and a pH ranging from about 9.5 to 12Ø Typically, a dwell 2 0 time of about 5 to 10 seconds is required to reach the desired range of thickness, with the optimum dwell time depending upon the desired thickness of gold as well as the level of current employed. The optimization of current density and dwell time is con-sidered to be a routine endeavor that is well within the capabilities of those having ordi-nary skill in the art and is not considered to constitute undue experimentation.
2 5 Addition agents such as wetters and brighteners may be included in the acid strike, nickel strike, or gold strike baths to enhance the strike characteristics. The composition and concentration of such addition agents are well-known in the art and hence do not form a part of this invention. At the conclusion of the deposition of a thin strike layer 26, the part is rinsed in cold running water in preparation for electro 3 0 plating an intermediate metal layer.
Once a thin strike layer 26 is in place, the intermediate metal layer 24 may then be electroplated to a preferred thickness of at least about 100 micro-inches (0.000254 cm). A thickness of less than about 100 micro-inches would likely not be sufficiently hard. Regardless of vvhether gold, rhodium, or palladium is chosen to serve as the intermediate layer 24, there are known techniques and electroplating baths to electroplate such a layer. Any of such known techniques may be employed in the practice of the invention to provide an intermediate metal layer 24 atop the thin strike layer 26. Since the intermediate metal layer 24 preferably comprises gold, further de-tail is provided below regarding the process of electroplating gold onto the strike layer 26. It is expected that the; process. for electroplating rhodium or palladium onto the strike layer 26 would be a~ialogous.
To electroplate an intermediate layer 24 of gold atop the strike layer 26, the portion 18 of the instrument to bc: plated is immersed in a gold electroplating bath, preferably according to a rack method. Any of the known gold electroplating baths may be employed in the practice o:f the invention. Preferably, Techni Gold -25, a pro-prietary non-cyanide gold plating bath commercially-available from Technic, Inc., is employed in the practice o~f the invention to achieve a gold layer 24 having a hardness ranging from about 130 t~o 180 on a Knoop scale. Rather than employ a gold metal anode, gold metal is prei:erably added to the solution as necessary throughout the plating process. A current of about 3 to 5 amps/ft2 (32.3 to 53.8 amps/mz) is impressed on the part, which serves as the cathode. Typically, a dwell time of about 12 minutes is required to plate about 100 micro-inch of gold using the Techni-Gold 25 bath in a 2 0 rack method. The optimization of current density and dwell time is considered to be a routine endeavor that is wc;ll within the capabilities of those having ordinary skill in the art and is not considered tn be undue. The Techni Gold - 25 gold plating bath is pref=
erably operated at a temperature ranging from about 120° to 140°F (49° to 60°C) and a pH ranging from about 8.8 to 10.7, with the pH being preferably adjusted using a 2 5 20% solution of sodium hydroxide.
Addition agents such as wetters and brighteners may also be included in the gold electroplating bath to enhance the plating characteristics. For example, a bright ener permits use of higher current densities to achieve a harder deposit. The composi tion and concentration of such adalition agents are well-known in the art and hence do 3 0 not form a part of this invention.
Following the ele~~troplating of the intermediate metal layer 24, a hot water rinse may be used if needed to remove contaminants. Finally, the electrosurgical in-strument may be dried, preferably with compressed air, in preparation for the applica-tion of a non-stick surface.
In the first embodiment of the present invention, that portion of the electrosur gical instrument (surfaces 20a, 20b, 22a, 22b} that has been plated with an intermedi ate metal layer is then coated with an intermediate metal layer 24 is then coated with a non-stick material 28 comprising a fluoropolymer material, with the fluoropolymer material preferably preceded by a coating of liquefied primer material (not shown).
Any of the primer materials commonly used as precursors to fluoropolymer material for electrosurgical instruments may be employed in the practice of the invention, such as primer materials commercially available from Whitford Corp. and DuPont. For aesthetic purposes, it is preferable that the primer coating be clear such that the un-derlying metal is visible. Preferably, the primer material is sprayed onto the metal-plated major surfaces 20a, 20b of the blade 18 using, for example, an airbrush tech-nique.
In the second embodiment of the present invention, only the major surfaces 20a, 20b of the portion 18 of the electrosurgical instrument that have been plated with an intermediate metal layer 24 are then coated with the non-stick material 28, as shown in FIG. 3b.
After the primer material is dried, the blade 18 is placed in a kiln oven for less 2 0 than about 5 minutes (preferably about 1 minute) at a temperature ranging from about 450° to 850°F (232° to 455°C). The optimum temperature within this range depends upon the particular primer material employed. After removal from the oven, the blade 18 and primer material are allowed to cool to room temperature.
Finally, a coat 28 of fluoropolymer material is applied to the primer material.
2 5 Suitably employed fluoropolymer materials include, but are not limited to poly-tetrafluoroethylene (PTFE) and fluorinated ethylenepropylene resin (FEP).
Preferably, the fluoropolymer material is sprayed onto the primer material, or in the absence of primer material, directly onto the intermediate metal layer 24. An air brush may be employed to effect a spray. After applying the fluoropolymer material, the blade 18 3 o and material are preferably allowed to dry for about one hour at room temperature.
The blade 18 is then placed in a preheated oven for less than about 5 minutes (preferably about 1 minute) at a temperature ranging from about 450° to 850°F (232°
to 455°C). The optimum temperature within this range depends upon the particular fluoropolymer material emiployed. .After removal from the oven, the coated blade 18 is allowed to cool to room temperature. Upon cooling, the blade 18 may be polished to a high sheen using a soft cotton cloth. to remove dirt and debris.
The total thickness of the non-stick coating 28 is preferably about 0.002 inch (0.005 cm). The non-stick coating :Z8 as defined herein includes both the primer mate-rial and the fluoropolymer material. Thus, if a coat of fluoropolymer material is em-ployed alone, it preferably has a thickness of about 0.002 inch.
Alternatively, if both a primer coat and fluoropolymer coat: are employed as the non-stick coating 28, the non-stick coating preferably has a total thickness of about 0.002 inch. If the non-stick 1 o coating 28 is too thick, it nnay be too soft and might be susceptible to cracking. On the other hand, if the non-stick; coating 28 is too thin, incomplete coverage of the interme-diate gold layer may result.
In the second embodiment of the present invention, the edges 22a, 22b may be protected during the deposition of the primer coat and the non-stick material 28 by use of a conventional mask on the edge, only, which is then removed following the depo sitions to expose the metal-coated edges. Alternatively, the entire portion 18 may be coated with the primer coat and the non-stick material 28 and the edges 22a, 22b ex-posed subsequent to the coatings by use of an abrasive or sharp-edged instrument to remove the coatings from the edge:. only.
2 0 The electrosurgical. instrument 10 manufactured and used in accordance with the present invention eliminates the need to choose between quick and efficient cau-terization during surgery and the prevention of tissue sticking to the instrument.
Rather, the present instrument retains the non-sticking capabilities of the prior art while enhancing the electrical conductivity of the instrument with gold plating. As 2 5 such, the length of time required for cauterization is minimized as is the amount of power necessary to achieve cauteri:aation. Furthermore, the process by which the pres-ent electrosurgical instrument is manufactured is relatively simple and easily auto-mated.
As indicated above; and as illustrated in FIG. 3b, the metal-coated edges 22a, 3 0 22b are not coated by the fluoropolymer or by the primer, and hence are exposed. Be cause the edges 22a, 22b are not coated by the fluoropolymer or by the primer, and thus are exposed, better c;lectrical conductivity is obtained to cut flesh along these edges and to cauterize flesh, yet the major surfaces 20a, 20b, being coated with the WO 98/49954 PCT/tJS97/11342 fluoropolymer coating, allow passage of the blade 18 through flesh without sticking, permitting easier cleaning of the blade and reducing surgical time. While cutting is not done by the major surfaces 20a, 20b, cauterizing may be done by these major sur-faces.
EXAMPLES
A comparison has been made between four electrosurgical instruments to il-lustrate the advantages realized in the practice of the invention. The stainless steel blades of the four electrosurgical instrurrlents were prepared for testing as follows:
~ Electrosurgical instrument "A": The stainless steel blade remained uncoated.
~ Electrosurgical instrument "B": The stainless steel blade was coated with TeflonTM in accordance with the teachings of U.S. Pat-ent No. 4,785,807.
~ Electrosurgical instrument "C": The stainless steel blade was se-quentially coated with a thin acid gold strike layer, a layer of gold having a thickness of about 100 micro-inch, a primer coat, and a polytetrafluoroethylene coating, all in accordance with the teach-2 0 ings of the first embodiment herein.
~ Electrosurgical instrument "D": The stainless steel blade was coated as in the case of the Electrosurgical instrument "C", except that the edges were free of the primer coat and the polytetrafluoro-ethylene coating, in accordance with the teachings of the second 2 5 embodiment of the present invention.
The four instruments were each employed in surgical procedures. The quantity of electrical energy made available to the instruments for purposes of inducing hemo-stasis during surgery was controlled by a power dial having an uncalibrated range from 1 to 10. Thus, while the particular amount of watts employed for each instrument 3 0 is unknown, the power dial setting indicates in relative terms the amount of electrical energy required such that a comparison between instruments may be made.
Observa-tions regarding power settings, tissue sticking, and tissue damage follow for each in-strument.
Electrasur~l instntment "A": This instrument required power settings ranging from about 3 to '7 to achieve hemostasis during surgery. Without a non-stick coating of any sort, this instrument sustained extensive tissue sticking such that the surgeon had to frequently clean the instrument during surgery, thus increasing the time of surgery.
Electrosurgical instrument "B": This instrument required power settings ranging from about 5 to 10 to achieve hemostasis, which is considerably more wattage than that required for instntment "A". As a result of the increased wattage, more tissue damage was sustained compared 'with instrument "A". Further, the increased voltage elevated the fire hazard associated with employing an electrosurgical instrument. On the other hand, less tissue: adhered to the TeflonTM-coated blade than the bare stainless steel blade of instrument "A", and any tissue that perchance did adhere to blade "B"
was readily cleaned. Thus, less surgical time was expended cleaning instrument "B"
than instrument "A".
Electrosur ic>' al instrument "C": This instrument required power settings ranging from about 3 to E>, which was a considerable improvement over the TeflonTM_ coated instrument "B" and even a slight improvement over the bare stainless steel 2 0 blade of instrument "A". The gold interlayer provided a more concentrated power source for hemostasis sc~ that cuts were cleaner. Accordingly, the amount of tissue damage observed for instrument "C" was comparable to that of instrument "A"
and much less than that of instrument "B". Further, like instrument "B", this instrument experienced little tissue adherence given its non-stick coating, and any tissue that did 2 5 stick was readily cleaned.
Electrosurgical imstrumer~t "D": This instrument required power settings ranging from about 1 to ~E, which was a noticeable improvement over even Electrosur-gical instrument "C". The lower power, which was concentrated to the edges, resulted in a better and smoother cut, with less damage to the tissue. There were fewer fumes 3 0 due to the lower setting, thereby posing less of a fire hazard.
In sum, it has been illustrated that an electrosurgical instrument made in ac-cordance with the preser.~t invention combines the advantages of prior art instruments while eliminating their significant disadvantages. More specifically, electrosurgical instruments "C" and "D" both conducted electrical energy better than the bare stain-less steel blade of electrosurgical instrument "A" so that lower power was possible to achieve hemostasis during surgery, thereby inflicting less tissue damage and posing a lesser fire hazard. Further, electrosurgical instruments "C" and "D" also exhibited a lesser tissue adherence on par with the TeflonTM-coated blade of instrument "B".
Essentially, it has been demonstrated that an electrosurgical instrument made in accordance with the present invention enables a surgeon to take advantage of a non-stick coating without subjecting patients to increased tissue damage deriving from the use of a diffused power source to achieve hemostasis.
l0 Thus, there has been disclosed an electrosurgical instrument having an inter-mediate metal layer topped by a non-stick coating. A method of enhancing the electri-cal conductivity of an electrosurgical instrument is also disclosed, along with a method of using the resulting electrosurgical instrument. It will be appreciated by those skilled in the art that various changes and modifications of an obvious nature may be made, and all such changes and modifications are considered to fall within the scope of the invention, as defined by the appended claims.
Claims (19)
1. ~An electrosurgical instrument to which electric current can be applied for at least one of cutting and cauterizing tissue, said electrosurgical instrument comprising:
(a) ~a stainless steel portion capable of conducting said electric current and having two major opposed surfaces connected by two edge surfaces;
(b) ~an intermediate layer on said major opposed surfaces and said edge surfaces, said intermediate layer comprising a substantially non-toxic metal having a hardness of at least about 130 on a Knoop scale and an electrical resistivity not exceeding about 15 microhm-cm at 20° C.; and (c) ~a non-stick coating on surfaces of the intermediate layer that overlie said major opposed surfaces, thereby leaving said two edge surfaces with said intermediate layer thereon exposed.
(a) ~a stainless steel portion capable of conducting said electric current and having two major opposed surfaces connected by two edge surfaces;
(b) ~an intermediate layer on said major opposed surfaces and said edge surfaces, said intermediate layer comprising a substantially non-toxic metal having a hardness of at least about 130 on a Knoop scale and an electrical resistivity not exceeding about 15 microhm-cm at 20° C.; and (c) ~a non-stick coating on surfaces of the intermediate layer that overlie said major opposed surfaces, thereby leaving said two edge surfaces with said intermediate layer thereon exposed.
2. ~The electrosurgical instrument of claim 1 further comprising a metal strike layer between said major opposed and edge surfaces and said intermediate layer.
3.~The electrosurgical instrument of claim 2 wherein said metal strike layer consists essentially of gold and ranges from about 0.000003 to 0.00005 inch in thickness.
4. ~The electrosurgical instrument of any one of claims 1 to 3 wherein said intermediate layer has a thickness of at least 0.0001 inch and comprises a metal selected from the group consisting of gold, rhodium, and palladium.
5. ~The electrosurgical instrument of claim 4 wherein said intermediate layer comprises gold.
6. ~The electrosurgical instrument of any one of claims 1 to 5 wherein said non-stick coating has a thickness of about 0.002 inch and comprises a layer of fluoropolymer material.
15~
15~
7. ~The electrosurgical instrument of claim 6 wherein said fluoropolymer material comprises polytetrafluoroethylene.
8.~The electrosurgical instrument of claim 6 or 7 wherein said non-stick coating further comprises a primer coat.
9. ~The electrosurgical instrument of claim 8 wherein said primer coat is substantially transparent to visible light.
10. ~A method for enhancing the electrical conductivity of an electrosurgical instrument used with a source of electrical energy during surgery to perform at least one of cutting and cauterizing tissue, said electrosurgical instrument comprising a stainless steel portion for receiving said electrical energy and having two major opposed surfaces connected by two edge surfaces thereon, said method comprising:
(a) plating on said major opposed and edge surfaces an intermediate layer comprising a substantially non-toxic metal having a hardness of at least about 130 on a Knoop scale and an electrical resistivity not exceeding about 15 microhm-cm at 20°C; and (b) coating surfaces of said intermediate layer with a non-stick coating that overlie said major opposed surfaces, thereby leaving said two edge surfaces with said intermediate layer thereon exposed;
wherein said electrical energy is conducted from at least one edge surface to cut said tissue and wherein said electrical energy is conducted from at least one edge surface, from at least one major opposed surface, or both, to cauterize said tissue.
(a) plating on said major opposed and edge surfaces an intermediate layer comprising a substantially non-toxic metal having a hardness of at least about 130 on a Knoop scale and an electrical resistivity not exceeding about 15 microhm-cm at 20°C; and (b) coating surfaces of said intermediate layer with a non-stick coating that overlie said major opposed surfaces, thereby leaving said two edge surfaces with said intermediate layer thereon exposed;
wherein said electrical energy is conducted from at least one edge surface to cut said tissue and wherein said electrical energy is conducted from at least one edge surface, from at least one major opposed surface, or both, to cauterize said tissue.
11. ~The method of claim 10 further comprising plating a metal strike layer on said major opposed and edge surfaces prior to step (a), said intermediate layer then being plated on said metal strike layer in step (a).
12. ~The method of claim 11 wherein said metal strike layer is formed on said major opposed and edge surfaces by either (a) performing an acid gold strike or (b) 16~
performing a nickel strike on said major opposed and edge surfaces and a non-acid gold strike thereover.
performing a nickel strike on said major opposed and edge surfaces and a non-acid gold strike thereover.
13. ~The method of claim 11 or 12 wherein said metal strike layer ranges from about 0.000003 to 0.00005 inch in thickness.
14. ~The method of any one of claims 10 to 13 wherein said intermediate layer has a thickness of at least 0.0001 inch and comprises a metal selected from the group consisting of gold, rhodium, and palladium.
15. ~The method of claim 14 wherein said intermediate layer comprises gold.
16. ~The method of any one of claims 10 to 15 wherein said non-stick coating has a thickness of about 0.002 inch and comprises a layer of fluoropolymer material.
17. ~The method of claim 16 wherein said fluoropolymer material comprises polytetrafluoroethylene.
18. ~The method of claim 16 or 17 wherein said non-stick coating further comprises a primer coat.
19. ~The method of claim 18 wherein said primer coat is substantially transparent to visible light.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US08/851,134 US5885281A (en) | 1995-05-19 | 1997-05-05 | Gold-plated electrosurgical instrument |
| US08/851,134 | 1997-05-05 | ||
| PCT/US1997/011342 WO1998049954A1 (en) | 1997-05-05 | 1997-06-27 | Gold-plated electrosurgical instrument |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2288671A1 CA2288671A1 (en) | 1998-11-12 |
| CA2288671C true CA2288671C (en) | 2005-11-22 |
Family
ID=25310053
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002288671A Expired - Fee Related CA2288671C (en) | 1997-05-05 | 1997-06-27 | Gold-plated electrosurgical instrument |
Country Status (8)
| Country | Link |
|---|---|
| US (1) | US5885281A (en) |
| EP (1) | EP1017324B1 (en) |
| AU (1) | AU3585297A (en) |
| CA (1) | CA2288671C (en) |
| DE (1) | DE69737738T2 (en) |
| HK (1) | HK1026597A1 (en) |
| MX (1) | MXPA99010115A (en) |
| WO (1) | WO1998049954A1 (en) |
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| US6042590A (en) * | 1997-06-16 | 2000-03-28 | Novomedics, Llc | Apparatus and methods for fallopian tube occlusion |
| US6059783A (en) * | 1997-06-26 | 2000-05-09 | Kirwan Surgical Products, Inc. | Electro-surgical forceps which minimize or prevent sticking of tissue |
| US6193718B1 (en) * | 1998-06-10 | 2001-02-27 | Scimed Life Systems, Inc. | Endoscopic electrocautery instrument |
| US6132427A (en) * | 1998-09-21 | 2000-10-17 | Medicor Corporation | Electrosurgical instruments |
| GB9909801D0 (en) * | 1999-04-28 | 1999-06-23 | Btg Int Ltd | Ultrasound detectable instrument |
| RU2238048C2 (en) * | 1999-07-30 | 2004-10-20 | Дрюккер Интернэшнл Бв | Method of forming protective fluorine atom layer on cutting blade of surgical instrument, cutting blade for surgical instrument, and a method of forming protective fluorine atom layer on blade of surgical instrument |
| US6293946B1 (en) * | 1999-08-27 | 2001-09-25 | Link Technology, Inc. | Non-stick electrosurgical forceps |
| US20040068307A1 (en) * | 2000-02-08 | 2004-04-08 | Gyrus Medical Limited | Surgical instrument |
| US6511479B2 (en) | 2000-02-28 | 2003-01-28 | Conmed Corporation | Electrosurgical blade having directly adhered uniform coating of silicone release material and method of manufacturing same |
| US6893435B2 (en) | 2000-10-31 | 2005-05-17 | Gyrus Medical Limited | Electrosurgical system |
| US6843789B2 (en) | 2000-10-31 | 2005-01-18 | Gyrus Medical Limited | Electrosurgical system |
| GB0026586D0 (en) | 2000-10-31 | 2000-12-13 | Gyrus Medical Ltd | An electrosurgical system |
| US6569163B2 (en) * | 2001-03-09 | 2003-05-27 | Quantumcor, Inc. | Wireless electrosurgical adapter unit and methods thereof |
| US6783525B2 (en) | 2001-12-12 | 2004-08-31 | Megadyne Medical Products, Inc. | Application and utilization of a water-soluble polymer on a surface |
| US6685704B2 (en) * | 2002-02-26 | 2004-02-03 | Megadyne Medical Products, Inc. | Utilization of an active catalyst in a surface coating of an electrosurgical instrument |
| US6951559B1 (en) | 2002-06-21 | 2005-10-04 | Megadyne Medical Products, Inc. | Utilization of a hybrid material in a surface coating of an electrosurgical instrument |
| US20040115477A1 (en) * | 2002-12-12 | 2004-06-17 | Bruce Nesbitt | Coating reinforcing underlayment and method of manufacturing same |
| ES2286487T3 (en) * | 2003-01-09 | 2007-12-01 | Gyrus Medical Limited | ELECTROCHIRURGICAL GENERATOR. |
| US7195627B2 (en) | 2003-01-09 | 2007-03-27 | Gyrus Medical Limited | Electrosurgical generator |
| ES2379172T3 (en) * | 2003-05-01 | 2012-04-23 | Covidien Ag | Coagulation suction device with dissection probe. |
| US7258689B2 (en) * | 2003-05-19 | 2007-08-21 | Matteo Tutino | Silver alloys for use in medical, surgical and microsurgical instruments and process for producing the alloys |
| US8814861B2 (en) | 2005-05-12 | 2014-08-26 | Innovatech, Llc | Electrosurgical electrode and method of manufacturing same |
| US7147634B2 (en) * | 2005-05-12 | 2006-12-12 | Orion Industries, Ltd. | Electrosurgical electrode and method of manufacturing same |
| US20070108083A1 (en) * | 2005-11-15 | 2007-05-17 | Sonon James A | Tray with fronting member, associated displays and methods |
| WO2009023579A2 (en) * | 2007-08-10 | 2009-02-19 | Keefer Edward W | Coating neural electrodes with carbon nanotubes and variations |
| WO2020041299A1 (en) * | 2018-08-20 | 2020-02-27 | Advanced Flexible Composites, Inc. | Nonstick cookware and materials, and methods of manufacture and use |
Family Cites Families (11)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US4248231A (en) * | 1978-11-16 | 1981-02-03 | Corning Glass Works | Surgical cutting instrument |
| US4785807B1 (en) * | 1987-02-24 | 1996-07-16 | American Medical Products Inc | Electrosurgical knife |
| US4958539A (en) * | 1988-02-29 | 1990-09-25 | Everest Medical Corporation | Method of making an electrosurgical spatula blade |
| US5197962A (en) * | 1991-06-05 | 1993-03-30 | Megadyne Medical Products, Inc. | Composite electrosurgical medical instrument |
| US5372600A (en) * | 1991-10-31 | 1994-12-13 | Instent Inc. | Stent delivery systems |
| US5480398A (en) * | 1992-05-01 | 1996-01-02 | Hemostatic Surgery Corporation | Endoscopic instrument with disposable auto-regulating heater |
| US5308311A (en) * | 1992-05-01 | 1994-05-03 | Robert F. Shaw | Electrically heated surgical blade and methods of making |
| US5342357A (en) * | 1992-11-13 | 1994-08-30 | American Cardiac Ablation Co., Inc. | Fluid cooled electrosurgical cauterization system |
| US5380320A (en) * | 1993-11-08 | 1995-01-10 | Advanced Surgical Materials, Inc. | Electrosurgical instrument having a parylene coating |
| US5352222A (en) * | 1994-03-15 | 1994-10-04 | Everest Medical Corporation | Surgical scissors with bipolar coagulation feature |
| US5643256A (en) * | 1995-05-19 | 1997-07-01 | Urueta; R. Wilfrido | Gold-plated electrosurgical instrument |
-
1997
- 1997-05-05 US US08/851,134 patent/US5885281A/en not_active Expired - Fee Related
- 1997-06-27 CA CA002288671A patent/CA2288671C/en not_active Expired - Fee Related
- 1997-06-27 EP EP97932377A patent/EP1017324B1/en not_active Expired - Lifetime
- 1997-06-27 AU AU35852/97A patent/AU3585297A/en not_active Abandoned
- 1997-06-27 DE DE69737738T patent/DE69737738T2/en not_active Expired - Fee Related
- 1997-06-27 MX MXPA99010115A patent/MXPA99010115A/en not_active IP Right Cessation
- 1997-06-27 WO PCT/US1997/011342 patent/WO1998049954A1/en active IP Right Grant
-
2000
- 2000-09-19 HK HK00105886A patent/HK1026597A1/en not_active IP Right Cessation
Also Published As
| Publication number | Publication date |
|---|---|
| EP1017324A1 (en) | 2000-07-12 |
| EP1017324A4 (en) | 2003-01-29 |
| CA2288671A1 (en) | 1998-11-12 |
| WO1998049954A1 (en) | 1998-11-12 |
| EP1017324B1 (en) | 2007-05-16 |
| MXPA99010115A (en) | 2002-07-30 |
| US5885281A (en) | 1999-03-23 |
| HK1026597A1 (en) | 2000-12-22 |
| DE69737738T2 (en) | 2008-01-31 |
| AU3585297A (en) | 1998-11-27 |
| DE69737738D1 (en) | 2007-06-28 |
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| EEER | Examination request | ||
| MKLA | Lapsed |