CA1281779C - Electrosurgery cauterizing blade with conductive pad to contact handle - Google Patents

Abstract

ELECTROSURGERY SURGICAL BLADE
ABSTRACT OF THE DISCLOSURE
An electro surgical instrument comprising a handle and a replaceable blade. The handle includes a blade receiving slot and means for clamping the proximal portion of the blade within the slot. Also formed internally of the handle and within the slot is a cavity for containing an electrical-to-mechanical transducer and a plurality of conductive terminal pad areas. The blade is provided with a pattern of conductors which are insulated from one another and which lead to contact pad areas on the distal portion of the blade. When the blade is appropriately inserted into the handle and clamped in place, the transducer abuts the blade and electrical contact is established to energize the conductors and the transducer whereby the blade may be vibrated at a frequency and amplitude to limit the build-up of tissue debris on the blade during an electro surgery procedure.

Description

ELECTROSURGERY SURGICAL BLADE
BACKGROUND OF TtlE INVENTION
1. Field of the Invention -- The present invention relate~ to a suryical implement, and, more particularly, relates to a surgical tooI for performing electro-surgical and electro-cautery procedures which provides for different modes of operation including a standard electro-surgical cutting blade and/or an electro-cautery blade and in which the blade is made to vibrate during use at a predetermined amplitude and frequency whereby cavitation results at the blade surface to free it of the build-up of organic debris.
II. Description of the Prior Art -- Various prior art electro-surgery and electro-cautery blades have been less than effective in that either a special material is required for the blades, or they comprise a combination of structures which are primarily ornamental and non-functional, and which require a considerable drive voltage which often cause undue tissue damage.
Some of the prior art devices do not allow for appropriate coupling of their blade member to their voltage sources and tend to be ineffectual.
Other types of prior art blades utilize extremely elaborate and complex electrical circuits with standard type of blade structures which do not, in the end, accomplish a desirable result o~ an effective surgical blade capable of operation in more than one mode.
One of the most severe problems with the prior art is the adhesioll of charred tissue and blood to the blade which shorts out the two conductors, and therefore, renders the blade useless as an electro-surgery device.
The present invention provides a tool for performing electro-surgical and/or electro-cautery procedures which, by 1~17'79 utilizing st~te-of-the-art s~micolld~ctor m~lsking t~chnology, c~n be lesigned to function as a standard surgical blade, or as a electrified blade. The present invention also provides a surgical tool which includes a capacitive blade. An important feature of the present invention is the provision of a piezo-ceramic, or other like element, coupled to a surgical blade for vibrating the blade so as to produce a cavitation effect which cleans the blade continuously during use.
SUMMARY OF THE INVENTION
The general purpose of the present invention is to provide an electro-cautery/electro-surgery tool which can be utilized as a standard surgical cutting blade with a sharp edge when no electrical power is applied to it; as an electro-surgical blade when a high voltage is applied between conductive surfaces sufficient to create a discharge for cutting and cauterizing of tissue; and as a low voltage electro-cautery tool where I2R losses heat the blade to cauterize the tissue.
Another principal object of the present invention is to provide an electro-surgical tool utilizing a capacitive type blade in which two conductors are separated by an insulator and driven by an alternating current.
Irrespective of the particular blade style, the present invention incorporates a piezo-ceramic or like transducer element for vibrating the blade sufficient to producé a cavitation effect, thereby preventing adherence of tissue debris on the blade. The transducer may be affixed to the blade member or disposed in the handle member intimate contact with the blade so as to vibrate the blade producing cavitation at the interface between the tissue and the blade.
In one embodiment of the present invention, there is provided an electro-cautery surgical tool, including a base member of a conductive material, such as stainless steel or the like, the base material fashioned in the form of a surgical blade with a sharpened edge leading to a point, layers of insulation . . .

~ 7~9 disposed on opposing sides of t:he bln~lf~, a s(~(~on(l l,ly-~l Or con~uctive material deposited over tlle ;nsul(~t;on rnatel-;al., and a plurality of geometrical gaps extend;ng through the sccond conductive layer which may be formed by selniconductor technology techniques including sandblasting by masking, laser machining, chemical action, electrode discharge machining (EDM), electron beam drilling, ion milling, or grinding, to define a conductive comb-shaped electrodes on the opposing sides of the blade.
Alternative embodiments of the present invention include opposing gaps on opposing surfaces of the blade, staggered gaps on opposing surfaces of the blade, holes partially through the second conductive portion to the first conductive portion of the blade, and a sandwiched alternating configuration of gaps.
Another alternative embodiment of the present invention comprises an electro-surgical tool which includes a conductive blade, a thick insulation layer extending across the conductive blade except at a defined sharpened cutting edge of the blade, a narrow conductor, such as a foil or the like, positioned slightly offset from the edge of the thick insulation, and a final thinner layer insulation covering the narrow conductor whereby the narrow conductor and the underlying blade conductor provide a capacitive effect for bioelectrically breaking down flesh.
An electrical-to-mechanical transducer, such as a piezo-ceramic, such as barium titanate, ca~ be attached to or mechanically coupled to the surgical blade for vibrating the blade so as to provide a cavitation effect.
One significant aspect and feature of the present invention is an electro-cautery/electro-surgical blade which can be utilized in a plurality of modes including a standard surgical blade, an electro-surgical blade mode, or a mode where the blade is heated during cauterization.
Another significant aspect and feature of the present invention is an electro-cautery/electro-surgical blade which utilizes a capacitive relationship between two conductors.

317~79 It is ~ principal ob j~ct ~l~r~o~ to provi~c ~n impl-ov~3 el tro-cautery/electro-surgical blade.
Another object is to provide an electro-cautery/electro-surgical blade which is ultrasonically vibrated.
A further object of the present invention is to provide a surgical blade which is disposable and produced by state-of-the-art semiconductor integrated circuit manufacturing processes.
Yet another object of the present invention is a surgical blade which uti.li~es a capacitive effect by the spacing of two conductors, the one conductor being insulated from a blade conductor, the blade conductor including a sharp edge.
A still further object of the present invention is to utilize an electrical-to-mechanical transducer to vibrate the blade at a predetermined amplitude and frequency at any time during a surgical procedure thereby preventing build-up of debris on the surgical blade, BRIEF DESCRIPTION OF THE DRAWINGS
Other objects and many of the attendant advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connecti.on with the accompanying drawings, in which like reference numerals designate like parts throughout the figures thereof and wherein:
FIG. 1 illustrates a cross-sectional view of an electro-cautery/surgical blade;
FIG. 2 illustrates a sectional view taken along line

2-2 of FIG. l;
FIG. 3 illustrates a sectional view taken along line

3-3 of FIG. l;
FIG. 4 illustrates the electro-cautery/surgical blade wired to an electro-surgical power supply;
FIG. 5 is a folded view illustrating an alternative embodiment of an electro-cautery/surgical blade;

1~ ~17~79 FIG. 6 illustrates a sectional view taken ~long lin~
of FIG. 5;
FIG. 7 illustrates a cross-sectional end view along line 7-7 of FIG. 5;

FIG. 8 illustrates a cross-sectional view of an alternative embodiment of a surgical blade;
FIG. 9 illustrates a sectional view taken along line 9-9 of FIG. 8;
FIG. 10 illustrates a cross-sectional end view along line 10-10 of FIG. 9;
FIG. ll illustrates another cross-sectional view of a further alternative embodiment;
FIG. 12 illustrates a sectional view taken along line 12-12 of FIG. 11;
FIG. 13 illustrates a cross-sectional end view taken along line 13-13 of FIG. 11;
FIG. 14 illustrates a plan view of a capacitive surgical blade;
FIG. 15 illustrates a sectional view taken along line 15-15 of FIG. 14;
FIG. 16 illustrates a plan view of a capacitive 8urgical blade with an ultrasonic transducer;
FIG. 17 illustrates a plan view of a resistive surgical blade with an ultrasonic transducer;
FIG. 18 illustrates a plan view of a blade holder with an ultrasonic transducer; and FIG. 19 illustrates a view taken along line 19-19 of FIG. 18.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a cross-sectional view of the blade portion 10 of an electro-cautery/electro-surgical tool including a conductive base member 12, such as stainless steel or the like, which is capable of being ground or honed to a sharp cutting edge. Stainless steel is particularly suitable for surgical 1~17t79 reasons in that it maintains ~ sh~ d~Je, nllcl it c~n be worke(l in machining and manuf~cturing point of view, and is ~ In~t~rial which is recognized in a surgical ~nd medical sense by the Food and Drug Administration. An insulation layer 14 is deposited over the conductive base 12 on both of its sides by known processes in the art. A second conductive material 16 is deposited over the insulation material 14 in a predetermined pattern. A plurality of gaps may be formed along the edge, the gaps being of a finite height and width. Processes, such as sandblasting, laser machining, chemical etching, electro-discharge machining (EDM), electron beam drilling, ion milling, grinding or the like, may be used to form a comb-like conductive electrode with opposing gaps with insulating material between the teeth. Subsequently, a sharp cutting edge is honed on the base member 12. The blade can take any predetermined geometrical configuration including one having a sharp point, a rounded point as illustrated in FIG. 1, or any other geometrical figure depending upon the type of surgery as well as the surgeon's preference.
FIG. 2 illustrates a view taken along line 2-2 of FIG.
1 where all numerals correspond to those elements previously described. The figure illustrates the opposing comb teeth and gaps which do not necessarily have to be opposed but can be staggered. Such opposing gaps are by way of example and for purposes of illustration only and not to be construed as limiting of the present invention.
FIG. 3 illustrates an end view of FIG. 1.
FIG. 4 illustrates the electro-surgical blade 10 mounted in a holder and connected to a surgical power supply 20 by way of a surgical power cord 22 and a line cord 24. The surgical power supply is capable of operating in three modes, 26, 28 and 30. The first is a standard surgical blade mode 26 where no power is applied to the blade. The second mode is an electro-surgical mode 28 where high voltage is applied between the , .

17'~9 conductive rnelllbers c~sing ~ slight di~sch~rge ~rc ~or cuLLinq ~I)d caucerizing. The third mode involves a low voltage appli~d between the conductive elements where heat is produced by I2R
losses solely for cauterization.
FIG. 5 illustrates a folded (two-sided) view of an electrode for electro-cautery and/or electro-surgery including a non-conductive, insulative support 102, a first conductor 104 and a second conductor 106 arranged in an opposing matrix and electrically interconnected with respect to each other across the working edge 108. The conductors 104 and 106 are comb-shaped and the teeth extend to the respective opposite side of the support 102 with the extensions being interleaved with the teeth on that side. The particular tip of the cutting edge is ground to a sharp point 108.
FIG. 6 illustrates a bottom view of FIG. 5 showing the particular configuration of the electrodes 104a-104n, 106a-106n, and insulative material 104.
FIG 7 illustrates a sectional view taken along line 7-7 of FIG. S where all numerals correspond to those elements previously described.
FIG. 8 illustrates a cross-sectional view of an electro-cautery surgical blade 200 including a conductive base member 202, an insulation layer 204, a second conductive material 206 and the insulation 204 to the base blade 202. The holes 208a-208n serve to distribute the electrical current in a predetermined desired fashion.
FIG. 9 illustrates a sectional view taken along line 9-9 of FIG. 8 where all numerals correspond to those elements previously described.
FIG. 10 illustrates a cross-sectional view taken along line 10-10 in FIG. 9 where all numerals correspond to those elements previously described.
FIG. 11 illustrates a cross-sectional view of an electro-surgical blade 303 including a conductive base member , ~2, insula~ion layer 30A, and a ,~colld co~-luct-iv~ In~ltf~ 3()~, ~ sited in layer 304 anc~ including a plurality of wr~3pE~ed-around segments 308 and gaps 310 alternating therebetween, as also illustrated in the cross-sectional view of EIG. 12.
FIG. 13 illustrates a view taken along line 13-13 of FIG. 11 where all numerals correspond to those elements previously described.

MODE OF OPERATION

The electro-cautery/electro-surgical blade is connected to a power supply which supplies power for three modes of operation, as a standard surgical blade, a mode of operation as an electro-surgical blade where a high voltage is applied between the conductive layers and the resulting discharge arc is used for cutting and cauterizing, or a mode of operation where the blade has applied to it a low voltage where heat is produced by the I2R
losses for cauterization.
The insulative material can be a ceramic, glass or other non-conductive material. The conductive material can be vapor-deposited or plated and photo-etched onto the insulative non-conductive material and can be silver, gold, aluminum or the like. The base member should be high-conductivity metal which has the property of being honed to a fine sharp edge. More so, a non-conductive insulative materia' which may be brought to an edge, such as glass or ceramic, with a photo-etched or vapor-deposited metal thereon is particularly desirable in this disclosed group of embodiments.

ALTERNATIVE_EMBODIMENT - CAPACITIVE BLADE

FIG. 14 illustrates a side view of a capacitive electro-cautery/electro-surgical blade including a blade conductor 400 with a sharp cutting edge 402 formed on the working edge thereof.
The right end of the bLade when viewed on FIG. 14 acts as a first electrical contact pad 401. A thick insulator 404, such as .005"
to .015" thick, is positioned over the blade conductor 400, as best illustrated in the cross-sectional view of FIG. 15. A

~ 73 nal-row cond~ctor 406 ~el-lnin~t~.s .lt n sr~cond c(>llL.lc~: I)nd 4(~3 ated [rom pad 401, and wraps around tlle forward upper edgc of the blade is illustrated in FIG. 14. A thin insulator 405 of a finite thickness of .001" to .002" is positioncd over the top of the narrow conductor 406 and subsequently over insulator 404, and is offset slightly below the lower edge of the thick insulator 404. The contact pads 401 and 408 provide for connection to a source of electrical current for impressing a capacitive charge across the thick blade conductor 400, insulator 404, and the thin, narrow conductor 406, thereby providing for dielectric breakdown when the blade is brought into contact with the flesh during the operation. The blade can mount in a blade holder, such as that illustrated in FIG. 18. The blade holder can include a screw or like for compression clamping about the blade and providing for electrical contact to the contact pads.

~ 7~9 FIG. 16 illustrates a plan view of a capacitlve electro-cautery blade 400 where all numerals correspond to those elements previously described. An electrical-to-mechanical transducer, such as an ultrasonic transducer 402 is affixed to the blade and includes two contact pads 422 and 424 for supplying power from an alternating current source to the transducer 420. contact pads 424 electrically and mechanically connects to the contact pad 401. The transducer 420 vibrates at a frequency determined by the power supply and at an amplitude which provides a cavitation effect at the selected frequency. The high frequency vibration of the blade prevents adherence of debris to the blade 400 during a surgical procedure. The transducer 420 can be powered independently or may be driven by the same power source used for energizing the blade.
ALTERNATIVE EMBODIMENT - RESISTIVE BLADE
FIG. 17 illustrates a plan view of a resistive electro-cautery blade 500 including a sharpened edge 502, a first contact pad area 504, a layer of insulation 506 on the conductive base but exposing the cutting edge 502, and a wrap-around exposed metal surface 508 including a second contact pad 510 deposited on or affixed to the layer 506. The resistive blade is similar to that type of blade described previously in FIGS. 1-13. A
transducer element 520, including contact points 522 and 524, is positioned in intimate contact with the contact surface 504. The contact point 524 mechanically and electrically connects to the contact pad 504. The operation of the blade of FIG. 17 in a vibratory mode is the same as the operation of FIGS. 14-16.
BLADE HOLDER
FIG. 18 illustrates a plan view of a blade holder with a vibratory transducer, another alternative embodiment of the --lQ--1~ ~17'~

present invention. The blade hold~r 600 includes a slot 602 extending through a forward portion of the handle and upwardly from a lower edge of the handle into the handle as also illustrated in FIG. 19. There is also provided a cavity 604 for supporting piezoelectric transducer 606 which thus locates it next to a surgical blade, all as later described in detail. The transducer 606, when mechanically compressed against the surgical blade, causes the surgical blade to vibrate in a direction transverse to the longitudinal axis of the blade during a power-on condition. In the alternative, the cavity may be configuredto accept the surgical blade with the transducer permanently affixed to the surgical blade. Then, of course, appropriate electrical contact pads would have to be provided to power the ultrasonic transducer.
The blade holder 600 also includes two contact pads 608 and 610 for making contact with a surgical blade so as to be able to selectively provide power to both the blade and the transducer 606. Screws 612 and 614 and wing nuts 616 and 618 provide for compression of the two halves of the blade holder 620 and 622 so as to compress the slit 602, and hold a surgical blade in frictional engagement within the holder 600.
A power source 624 including three power cables 620a-620c provides power to the surgical blade as well as to the transducer. The power cables include a common wire 620a, a transducer wire 620b and a surgical blade power wire 620c. The power source 624 can be switchable and pulsed as required, including a transducer waveform source 626a and switching device 626b, and blade waveform source 628a and switching device 628b.
This invention has been described herein in considerable detail in order to comply with the Patent Statutes and to provide 1~17t~9 those skilled in the art with the information needed to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by specifically different equipment and devices, and that various modifications, both as to equipment details and operating procedures, can be accomplished without departing from the scope of the invention itself.
What is claimed is:

, , . .
.

Claims (5)

The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:

1. An electro-surgical instrument comprising:
(a) a conductive blade member having a sharp edge;
(b) a layer of insulation covering said conductive blade with the exception of said sharp edge;
(c) a conductive strip located adjacent to the edge portion of said insulation layer proximate said sharp edge, said conductive strip being joined to a conductive pad area on said layer of insulation; and (d) a further layer of insulation covering said conductive strip except at said conductive pad area.

2. The instrument as in claim 1 wherein said conductive blade and said conductive strip comprise a capacitor.

3. The instrument as in claim 1 wherein said layer of insulation is in the rage of from .005 to .015 inches thick.

4. The instrument as in claim 1 wherein said conductive strip is in the range of from .01 to .03 inches thick.

5. The instrument as in claim 1 wherein said further layer of insulation is in the rage of from .001 to .024 inches thick.