Fluid-Assisted Electrosurgical Devices, and Methods of Manufacture Thereof

Abstract

This invention provides a fluid-assisted electrosurgical device to treat tissue in a presence of radio frequency energy and a fluid provided from the device. The device comprises a handle, a rigid shaft member distal to the handle, and at least one electrode distal to the shaft member. The shaft member comprises a shaft member first body and a shaft member second body joined together along a length of the shaft member. The shaft member further comprises a plurality of longitudinally oriented shaft member passages, with each of the passages having a length defined by the shaft member first body and the shaft member second body.

1 . An electrosurgical device comprising:
 a handle;   a rigid shaft member distal to the handle, the shaft member comprising a shaft member first body and a shaft member second body, the shaft member first body and the shaft member second body joined together along a length of the shaft member;   the shaft member including a plurality of longitudinally oriented shaft member passages, each of the passages having a length defined by the shaft member first body and the shaft member second body; and   at least one electrode distal to the shaft member.   
     
     
         2 . The device of  claim 1  wherein:
 the plurality of shaft member passages includes an electrical passage containing an electrical conductor; and 
 the electrical conductor is electrically coupled to the at least one electrode. 
 
     
     
         3 . The device of  claim 2  wherein:
 the electrical conductor extends from a proximal end of the shaft member to a distal end of the shaft member and into contact with the at least one electrode. 
 
     
     
         4 . The device of  claim 3  wherein:
 the electrical conductor and the at least one electrode contact one another within a receptacle for the electrode at a distal end of the shaft member. 
 
     
     
         5 . The device of  claim 2  wherein:
 the electrical conductor and at least one of the shaft member first body and the shaft member second body have interconnecting mating features to position the electrical conductor relative to at least one of the shaft member first body and a shaft member second body. 
 
     
     
         6 . The device of  claim 5  wherein:
 the interconnecting mating features comprises a keyway and a key configured to interconnect with the keyway. 
 
     
     
         7 . The device of  claim 2  wherein:
 the electrical conductor is made of sheet metal. 
 
     
     
         8 . The device of  claim 1  wherein:
 the at least one electrode comprises a first electrode and a second electrode; 
 the plurality of shaft member passages includes a first electrical passage and a second electrical passage; 
 the first electrical passage contains a first electrical conductor which is electrically coupled to the first electrode; and 
 a second electrical passage contains a second electrical conductor which is electrically coupled to the second electrode. 
 
     
     
         9 . The device of  claim 8  wherein:
 the first electrical passage is isolated from the second electrical passage. 
 
     
     
         10 . The device of  claim 1  wherein:
 the plurality of shaft member passages includes a fluid delivery passage; and 
 the fluid delivery passage is in fluid communication with at least one fluid outlet configured to provide fluid to the at least one electrode. 
 
     
     
         11 . The device of  claim 10  wherein:
 the at least one fluid outlet is at least partially defined by the at least one electrode. 
 
     
     
         12 . The device of  claim 10  wherein:
 the shaft member fluid delivery passage passes through a shaft member connector portion configured to connect the shaft member fluid delivery passage with fluid delivery tubing within the handle; and 
 the shaft member connector portion is defined by at least one of the shaft member first body and the shaft member second body. 
 
     
     
         13 . The device of  claim 12  wherein:
 the shaft member connector portion comprises a barbed connector portion. 
 
     
     
         14 . The device of  claim 10  wherein:
 the at least one electrode comprises a first electrode and a second electrode; 
 the at least one fluid outlet configured to provide fluid to the at least one electrode comprises a first fluid outlet configured to provide fluid to the first electrode and second fluid outlet configured to provide fluid to the second electrode; 
 the shaft member fluid delivery passage includes a first branch and a second branch; 
 the shaft member fluid delivery passage first branch is in fluid communication with the first fluid outlet configured to provide fluid to the first electrode; and 
 the shaft member fluid delivery passage second branch is in fluid communication with the second fluid outlet configured to provide fluid to the second electrode. 
 
     
     
         15 . The device of  claim 14  wherein:
 the first fluid outlet is at least partially defined by the first electrode; and 
 the second fluid outlet is at least partially defined by the second electrode. 
 
     
     
         16 . The device of  claim 14  wherein:
 the first electrode includes a first electrode fluid delivery passage in fluid communication with the shaft member fluid delivery passage first branch; and 
 the second electrode includes a second electrode fluid delivery passage in fluid communication with the shaft member fluid delivery passage second branch. 
 
     
     
         17 . The device of  claim 14  wherein:
 the first electrode fluid delivery passage passes through a first electrode connector portion configured to connect the first electrode to the shaft member; and 
 the second electrode fluid delivery passage passes through a second electrode connector portion configured to connect the second electrode to the shaft member. 
 
     
     
         18 . The device of  claim 14  wherein:
 the first electrode connector portion comprises a barbed connector portion; and 
 the second electrode connector portion comprises a barbed connector portion. 
 
     
     
         19 . The device of  claim 1  wherein:
 the shaft member first body and the shaft member second body are joined together by a weld line. 
 
     
     
         20 . The device of  claim 19  wherein:
 the plurality of longitudinally oriented shaft member passages are separated from one another along a common weld line. 
 
     
     
         21 . The device of  claim 1  wherein:
 the plurality of longitudinally oriented shaft member passages are along side one another. 
 
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         22 . The device of  claim 1  wherein:
 the plurality of longitudinally oriented shaft member passages are parallel. 
 
     
     
         23 . The device of  claim 1  wherein:
 the shaft member first body is made of a thermoplastic material; and 
 the shaft member second body is made of a thermoplastic material.