USRE40156E1 - Methods for repairing damaged intervertebral discs - Google Patents

Abstract

Apparatus and methods for treating an intervertebral disc by ablation of disc tissue. A method of the invention includes positioning at least one active electrode within the intervertebral disc, and applying at least a first high frequency voltage between the active electrode(s) and one or more return electrode(s), wherein the volume of the nucleus pulposus is decreased, pressure exerted by the nucleus pulposus on the annulus fibrosus is reduced, and discogenic pain of a patient is alleviated. In other embodiments, a curved or steerable probe is guided to a specific target site within a disc to be treated, and the disc tissue at the target site is ablated by application of at least a first high frequency voltage between the active electrode(s) and one or more return electrode(s). A method of making an electrosurgical probe is also disclosed.

Description

CROSS-REFERENCES TO RELATED APPLICATIONS

The present inventionThis application is a REISSUE application of U.S. patent application Ser. No.09/676,194, filed Sep.28,2000. U.S. patent application Ser. No.09/676,194, filed Sep.28,2000, now U.S. Pat. No.6,602,248claims priority from U.S. Provisional Application No. 60/224,107, filed Aug.9, 2000, and from PCT and is also a continuation-in-part application of InternationalApplication No. PCT/US00/13706, filed May17, 2000, and which claims priorityfrom U.S. patent application Ser. No. 09/316,472, filed May21, 1999, now U.S. Pat. No. 6,624,650, which is a continuation-in-part of U.S. patent application Ser. No. 09/295,687, filed Apr.21, 1999, now U.S. Pat. No. 6,203,542,and U.S. patent application Ser. Nos.09/054,323, now U.S. Pat. No. 6,063,079,and09/268,616, now U.S. Pat. No. 6,159,208,filed Apr. 2, 1998 and Mar. 15, 1999, respectively, each of which are continuation-in-parts of U.S. patent application Ser. No. 08/990,374, filed Dec.15, 1997, now U.S. Pat. No. 6,109,268,which is a continuation-in-part of U.S. patent application Ser. No. 08/485,219, filed on Jun.7, 1995, now U.S. Pat. No. 5,697,281,the complete disclosures of which are incorporated herein by reference for all purposes. This applicationU.S. patent application Ser. No.09/676,194, filed Sep.28,2000, is also a continuation-in-part of U.S. patent application Ser. No. 09/026,851, filed Feb.20, 1999, now U.S. Pat. No. 6,277,112,which is a continuation-in-part of U.S. patent application Ser. No. 08/690,159, filed Jul.18, 1996, now U.S. Pat. No. 5,902,272,the complete disclosure of which is incorporated herein by reference for all purposes.

The present invention is related to commonly assigned U.S. patent application Ser. No. 09/181,926, filed Oct. 28, 1998, U.S. patent application Ser. No. 09/130,804, filed Aug.7, 1998, now U.S. Pat. No. 6,045,532, U.S. patent application Ser. No. 09/058,571, filed on Apr.10, 1998, now U.S. Pat. No. 6,142,992, U.S. patent application Ser. No. 09/248,763, filed Feb.12, 1999, now U.S. Pat. No. 6,149,620, U.S. patent application Ser. No. 09/026,698, filed Feb.20, 1998, now U.S. Pat. No. 6,620,155, U.S. patent application Ser. No. 09/074,020, filed on May6, 1998, now U.S. Pat. No. 6,363,937, U.S. patent application Ser. No. 09/010,382, filed Jan.21, 1998, now U.S. Pat. No. 6,190,381, U.S. patent application Ser. No. 09/032,375, filed Feb.27, 1998, now U.S. Pat. No. 6,355,032, U.S. patent application Ser. Nos. 08/977,845, filed on Nov.25, 1997, now U.S. Pat. No. 6,210,402; 08/942,580, filed on Oct.2, 1997, now U.S. Pat. No. 6,159,194, U.S. patent application Ser. No. 08/753,227, filed on Nov.22, 1996, now U.S. Pat. No. 5,873,855, U.S. patent application Ser. No. 08/687,792, filed on Jul.18, 1996, now U.S. Pat. No. 5,843,019, and PCT International Application, U.S. National Phase Ser. No. PCT/US94/05168 filed on May 10, 1994, now U.S. Pat. No. 5,697,909, which was a continuation-in-part of U.S. patent application Ser. No. 08/059,681, filed on May10, 1993, now abandoned,which was a continuation-in-part of U.S. patent application Ser. No. 07/958,977, filed on Oct.9, 1992 now U.S. Pat. No. 5,366,443, which was a continuation-in-part of U.S. patent application Ser. No. 07/817,575, filed on Jan.7, 1992, now abandoned,the complete disclosures of which are incorporated herein by reference for all purposes. The present invention is also related to commonly assigned U.S. Pat. No. 5,697,882, filed Nov. 22, 1995, the complete disclosure of which is incorporated herein by reference for all purposes.

BACKGROUND OF THE INVENTION

The present invention relates to a medical apparatus having a distal curved configuration which avoids contact of the apparatus distal end with an introducer device. The present invention also relates to the field of electrosurgery, and more particularly to surgical devices and methods which employ high frequency electrical energy to treat tissue in regions of the spine. The present invention is particularly suited for the treatment of the discs, cartilage, ligaments, and other tissue within the vertebral column.

The major causes of persistent, often disabling, back pain are disruption of the disc annulus, chronic inflammation of the disc, contained and non-contained herniation, and relative instability of the vertebral bodies surrounding a given disc, such as the instability that often occurs due to a stretching of the interspinous tissue surrounding the vertebrae. Intervertebral discs mainly function to cushion and tether the vertebrae, while the interspinous tissue (i.e., tendons and cartilage, and the like) function to support the vertebrae so as to provide flexibility and stability to the patient's spine.

Spinal discs comprise a central hydrophilic cushion, the nucleus pulposus, surrounded by a multi-layered fibrous ligament, the annulus fibrous. As discs degenerate, they lose their water content and height, bringing the adjoining vertebrae closer together. This results in a weakening of the shock absorption properties of the disc and a narrowing of the nerve openings in the sides of the spine which may pinch these nerves. This disc degeneration can eventually cause back and leg pain. Weakness in the annulus from degenerative discs or disc injury can allow fragments of nucleus pulposus from within the disc space to migrate through the annulus fibrosus and into the spinal canal. There, displaced nucleus pulposus tissue, or protrusion of the annulus fibrous, e.g., due to herniation, may impinge on spinal nerves or nerve roots. A weakening of the annulus fibrosus can cause the disc to bulge, e.g., a contained herniation, and the mere proximity of the nucleus pulposus or the damaged annulus to a nerve can cause direct pressure against the nerve, resulting in pain and sensory and motor deficit.

Often, inflammation from disc herniation can be treated successfully by non-surgical means, such as rest, therapeutic exercise, oral anti-inflammatory medications or epidural injection of corticosteriods. Such treatments result in a gradual but progressive improvement in symptoms and allow the patient to avoid surgical intervention.

In some cases, the disc tissue is irreparably damaged, thereby necessitating removal of a portion of the disc or the entire disc to eliminate the source of inflammation and pressure. In more severe cases, the adjacent vertebral bodies must be stabilized following excision of the disc material to avoid recurrence of the disabling back pain. One approach to stabilizing the vertebrae, termed spinal fusion, is to insert an interbody graft or implant into the space vacated by the degenerative disc. In this procedure, a small amount of bone may be grafted and packed into the implants. This allows the bone to grow through and around the implant, fusing the vertebral bodies and preventing reoccurrence of the symptoms.

Until recently, surgical spinal procedures resulted in major operations and traumatic dissection of muscle and bone removal or bone fusion. To overcome the disadvantages of traditional traumatic spine surgery, minimally invasive spine surgery was developed. In endoscopic spinal procedures, the spinal canal is not violated and therefore epidural bleeding with ensuing scarring is minimized or completely avoided. In addition, the risk of instability from ligament and bone removal is generally lower in endoscopic procedures than with open procedures. Further, more rapid rehabilitation facilitates faster recovery and return to work.

Minimally invasive techniques for the treatment of spinal diseases or disorders include chemonucleolysis, laser techniques, and mechanical techniques. These procedures generally require the surgeon to form a passage or operating corridor from the external surface of the patient to the spinal disc(s) for passage of surgical instruments, implants and the like. Typically, the formation of this operating corridor requires the removal of soft tissue, muscle or other types of tissue depending on the procedure (i.e., laparascopic, thoracoscopic, arthoroscopic, back, etc.). This tissue is usually removed with mechanical instruments, such as pituitary rongeurs, curettes, graspers, cutters, drills, microdebriders and the like. Unfortunately, these mechanical instruments greatly lengthen and increase the complexity of the procedure. In addition, these instruments might sever blood vessels within this tissue, usually causing profuse bleeding that obstructs the surgeon's view of the target site.

Once the operating corridor is established, the nerve root is retracted and a portion or all of the disc is removed with mechanical instruments, such as a pituitary rongeur. In addition to the above problems with mechanical instruments, there are serious concerns because these instruments are not precise, and it is often difficult, during the procedure, to differentiate between the target disc tissue, and other structures within the spine, such as bone, cartilage, ligaments, nerves and non-target tissue. Thus, the surgeon must be extremely careful to minimize damage to the cartilage and bone within the spine, and to avoid damaging nerves, such as the spinal nerves and the dura mater surrounding the spinal cord.

Lasers were initially considered ideal for spine surgery because lasers ablate or vaporize tissue with heat, which also acts to cauterize and seal the small blood vessels in the tissue. Unfortunately, lasers are both expensive and somewhat tedious to use in these procedures. Another disadvantage with lasers is the difficulty in judging the depth of tissue ablation. Since the surgeon generally points and shoots the laser without contacting the tissue, he or she does not receive any tactile feedback to judge how deeply the laser is cutting. Because healthy tissue, bones, ligaments and spinal nerves often lie within close proximity of the spinal disc, it is essential to maintain a minimum depth of tissue damage, which cannot always be ensured with a laser.

Monopolar and bipolar radiofrequency devices have been used in limited roles in spine surgery, such as to cauterize severed vessels to improve visualization. Monopolar devices, however, suffer from the disadvantage that the electric current will flow through undefined paths in the patient's body, thereby increasing the risk of undesirable electrical stimulation to portions of the patient's body. In addition, since the defined path through the patient's body has a relatively high impedance (because of the large distance or resistivity of the patient's body), large voltage differences must typically be applied between the return and active electrodes in order to generate a current suitable for ablation or cutting of the target tissue. This current, however, may inadvertently flow along body paths having less impedance than the defined electrical path, which will substantially increase the current flowing through these paths, possibly causing damage to or destroying surrounding tissue or neighboring peripheral nerves.

Other disadvantages of conventional RF devices, particularly monopolar devices, is nerve stimulation and interference with nerve monitoring equipment in the operating room. In addition, these devices typically operate by creating a voltage difference between the active electrode and the target tissue, causing an electrical arc to form across the physical gap between the electrode and tissue. At the point of contact of the electric arcs with tissue, rapid tissue heating occurs due to high current density between the electrode and tissue. This high current density causes cellular fluids to rapidly vaporize into steam, thereby producing a “cutting effect” along the pathway of localized tissue heating. Thus, the tissue is parted along the pathway of evaporated cellular fluid, inducing undesirable collateral tissue damage in regions surrounding the target tissue site. This collateral tissue damage often causes indiscriminate destruction of tissue, resulting in the loss of the proper function of the tissue. In addition, the device does not remove any tissue directly, but rather depends on destroying a zone of tissue and allowing the body to eventually remove the destroyed tissue.

Many patients experience discogenic pain due to defects or disorders of intervertebral discs. Such disc defects include annular fissures, fragmentation of the nucleus pulposus, and contained herniation. A common cause of pain related to various disc disorders is compression of a nerve root by the disc. In many patients for whom major spinal surgery is not indicated, discogenic pain naturally diminishes in severity over an extended period of time, perhaps several months. There is a need for a minimally invasive method to treat such patients in order to alleviate the chronic, and often debilitating, pain associated with spinal nerve root compression. The instant invention provides methods for decompressing nerve roots by ablation of disc tissue at relatively low temperatures during a percutaneous procedure, wherein the volume of the disc is decreased and discogenic pain is alleviated.

SUMMARY OF THE INVENTION

The present invention provides systems, apparatus, and methods for selectively applying electrical energy to structures within a patient's body, such as the intervertebral disc. The systems and methods of the present invention are useful for shrinkage, ablation, resection, aspiration, and/or hemostasis of tissue and other body structures in open and endoscopic spine surgery. In particular, the present invention includes a method and system for debulking, ablating, and shrinking the disc.

The present invention further relates to an electrosurgical probe including an elongated shaft having first and second curves in the distal end portion of the shaft, wherein the shaft can be rotated within an intervertebral disc to contact fresh tissue of the nucleus pulposus. The present invention also relates to an electrosurgical probe including an elongated shaft, wherein the shaft distal end can be guided to a specific target site within a disc, and the shaft distal end is adapted for localized ablation of targeted disc tissue. The present invention further relates to a probe having an elongated shaft, wherein the shaft includes an active electrode, an insulating collar, and an outer shield, and wherein the active electrode includes a head having an apical spike and a cusp. The present invention still further relates to a method for ablating disc tissue with an electrosurgical probe, wherein the probe includes an elongated shaft, and the shaft distal end is guided to a specific target site within a disc.

In one aspect, the present invention provides a method of treating a herniated intervertebral disc. The method comprises positioning at least one active electrode within the intervertebral disc. High frequency voltage is applied between the active electrode(s) and one or more return electrode(s) to debulk, ablate, coagulate and/or shrink at least a portion of the nucleus pulposus and/or annulus. The high frequency voltage effects a controlled depth of thermal heating to reduce the water content of the nucleus pulposus, thereby debulking the nucleus pulposus and reducing the internal pressure on the annulus fibrosis.

In an exemplary embodiment, an electrically conductive media, such as isotonic saline or an electrically conductive gel, is delivered to the target site within the intervertebral disc prior to delivery of the high frequency energy. The conductive media will typically fill the entire target region such that the active electrode(s) are submerged throughout the procedure. In other embodiments, the extracellular conductive fluid (e.g., the nucleus pulposus) in the patient's disc may be used as a substitute for, or as a supplement to, the electrically conductive media that is applied or delivered to the target site. For example, in some embodiments, an initial amount of conductive media is provided to initiate the requisite conditions for ablation. After initiation, the conductive fluid already present in the patient's tissue is used to sustain these conditions.

In another aspect, the present invention provides a method of treating a disc having a contained herniation or fissure. The method comprises introducing an electrosurgical instrument into the patient's intervertebral disc either percutaneously or through an open procedure. The instrument is steered or otherwise guided into close proximity to the contained herniation or fissure and a high frequency voltage is applied between an active electrode and a return electrode so as to debulk the nucleus pulposus adjacent the contained herniation or fissure. In some embodiments a conductive fluid is delivered into the intervertebral disc prior to applying the high frequency voltage to ensure that sufficient conductive fluid exists for plasma formation and to conduct electric current between the active and return electrodes. Alternatively, the conductive fluid can be delivered to the target site during the procedure. The heating delivered through the electrically conductive fluid debulks the nucleus pulposus, and reduces the pressure on the annulus fibrosus so as to reduce the pressure on the affected nerve root and alleviate neck and back pain.

In another aspect, the present invention provides a method for treating degenerative intervertebral discs. The active electrode(s) are advanced into the target disc tissue in an ablation mode, where the high frequency voltage is sufficient to ablate or remove the nucleus pulposus through molecular dissociation or disintegration processes. In these embodiments, the high frequency voltage applied to the active electrode(s) is sufficient to vaporize and electrically conductive fluid (e.g., gel, saline and/or intracellular fluid) between the active electrode(s) and the tissue. Within the vaporized fluid, an ionized plasma is formed and charged particles (e.g., electrons) cause the molecular breakdown or disintegration of several cell layers of the nucleus pulposus. This molecular dissociation is accompanied by the volumetric removal of the tissue. This process can be precisely controlled to effect the volumetric removal of tissue as thin as 10 microns to 150 microns with minimal heating of, or damage to, surrounding or underlying tissue structures. A more complete description of this phenomenon is described in commonly assigned U.S. Pat. No. 5,697,882 the complete disclosure of which is incorporated herein by reference.

An apparatus according to the present invention generally includes a shaft having proximal and distal end portions, an active electrode at the distal end and one or more connectors for coupling the active electrode to a source of high frequency electrical energy. The probe or catheter may assume a wide variety of configurations, with the primary purpose being to introduce the electrode assembly into the patient's disc (in an open or endoscopic procedure) and to permit the treating physician to manipulate the electrode assembly from a proximal end of the shaft. The probe shaft can be flexible, curved, or steerable so as to allow the treating physician to move the active electrode into close proximity of the region of the disc, e.g., herniation, to be treated. The electrode assembly includes one or more active electrode(s) and a return electrode spaced from the active electrode(s) either on the instrument shaft or separate from the instrument shaft.

The active electrode(s) may comprise a single active electrode, or an electrode array, extending from an electrically insulating support member, typically made of an inorganic material such as ceramic, silicone or glass. The active electrode will usually have a smaller exposed surface area than the return electrode, such that the current densities are much higher at the active electrode than at the return electrode. Preferably, the return electrode has a relatively large, smooth surface extending around the instrument shaft to reduce current densities, thereby minimizing damage to adjacent tissue.

In another aspect, the present invention provides a method of treating an intervertebral disc, the method comprising contacting at least a first region of the intervertebral disc with at least one active electrode of an electrosurgical system. The at least one active electrode may be disposed on the distal end portion of a shaft of the electrosurgical system. A first high frequency voltage is applied between the active electrode(s) and one or more return electrode(s) such that at least a portion of the nucleus pulposus is ablated, and the volume of the disc's nucleus pulposus is decreased. After ablation of disc tissue at the first region of the intervertebral disc, other regions of the disc may be contacted with the at least one active electrode for ablation of disc tissue at the other regions of the disc. In one embodiment of the invention, axial translation of the at least one active electrode within the disc while applying the first high frequency voltage, leads to formation of a channel within the treated disc. The diameter of such a channel may be increased by rotating the at least one active electrode about the longitudinal axis of the shaft while applying the first high frequency voltage. Optionally, after a channel has been formed in the disc, disc tissue in the vicinity of the channel may be coagulated, or made necrotic, by applying a second high frequency voltage, wherein the second high frequency voltage may have different parameters as compared with the first high frequency voltage.

In another aspect, the present invention provides a method for treating an intervertebral disc, wherein the method involves providing an electrosurgical system including a probe having a shaft and a handle, the shaft having at least one active electrode located on the distal end portion of the shaft, and wherein the shaft distal end portion includes a pre-defined bias. The method further involves inserting the shaft distal end portion within the disc, and ablating at least a portion of the nucleus pulposus tissue from the disc such that the volume of the disc is decreased with minimal collateral damage to non-target tissue within the disc. The ablating step involves applying a high frequency voltage between the at least one active electrode and at least one return electrode. The high frequency voltage is sufficient to vaporize an electrically conductive fluid (e.g., a gel, isotonic saline, and/or tissue fluid) located between the at least one active electrode and the target tissue. Within the vaporized fluid a plasma is formed, and charged particles (e.g., electrons) are accelerated towards the nucleus pulposus to cause the molecular dissociation of nucleus pulposus tissue at the site to be ablated. This molecular dissociation is accompanied by the volumetric removal of disc tissue at the target site.

In one embodiment, inserting the shaft distal end portion in the disc involves advancing the shaft distal end portion via an introducer needle, the introducer needle having a lumen and a needle distal end, such that when the shaft distal end portion is advanced distally beyond the needle distal end, the at least one active electrode does not make contact with the needle distal end. One or more stages in the treatment or procedure may be performed under fluoroscopy to allow visualization of the shaft within the disc to be treated. Visualization of the shaft may be enhanced by inclusion of a radiopaque tracking device on the distal end of the shaft. The depth of penetration of the shaft into a disc can be monitored by one or more depth markings on the shaft.

In another aspect of the invention, the method further comprises retracting the shaft distal end portion proximally within the lumen of the introducer needle, wherein the at least one active electrode does not make contact with the needle distal end.

In another aspect of the invention, the shaft of the electrosurgical system includes a shield, and a distal insulating collar. In yet another aspect of the invention, the at least one active electrode includes an apical spike and a cusp. Applicants have found that an active electrode having an apical spike and a cusp promotes high current density in the vicinity of the active electrode.

For a further understanding of the nature and advantages of the invention, reference should be made to the following description taken in conjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an electrosurgical system incorporating a power supply and an electrosurgical probe for tissue ablation, resection, incision, contraction and for vessel hemostasis according to the present invention;

FIG. 2 schematically illustrates one embodiment of a power supply according to the present invention;

FIG. 3 illustrates an electrosurgical system incorporating a plurality of active electrodes and associated current limiting elements;

FIG. 4 is a side view of an electrosurgical probe according to the present invention;

FIG. 5 is a view of the distal end portion of the probe ofFIG. 4

FIG. 6 is an exploded view of a proximal portion of an electrosurgical probe;

FIGS. 7A and 7B are perspective and end views, respectively, of an alternative electrosurgical probe incorporating an inner fluid lumen;

FIGS. 8A-8C are cross-sectional views of the distal portions of three different embodiments of an electrosurgical probe according to the present invention;

FIGS. 9-12 are end views of alternative embodiments of the probe ofFIG. 4, incorporating aspiration electrode(s);

FIG. 13 is a side view of the distal portion of the shaft of an electrosurgical probe, according to one embodiment of the invention;

FIGS. 14A-14C illustrate an alternative embodiment incorporating a screen electrode;

FIGS. 15A-15D illustrate four embodiments of electrosurgical probes specifically designed for treating spinal defects;

FIG. 16 illustrates an electrosurgical system incorporating a dispersive return pad for monopolar and/or bipolar operations;

FIG. 17 illustrates a catheter system for electrosurgical treatment of intervertebral discs according to the present invention;

FIGS. 18-22 illustrate a method of performing a microendoscopic discectomy according to the principles of the present invention;

FIGS. 23-25 illustrates another method of treating a spinal disc with one of the catheters or probes of the present invention;

FIG. 26A is a side view of an electrosurgical probe according to the invention;

FIG. 26B is a side view of the distal end portion of the electrosurgical probe ofFIG. 26A;

FIG. 27A is a side view of an electrosurgical probe having a curved shaft;

FIG. 27B is a side view of the distal end portion of the curved shaft ofFIG. 27A, with the shaft distal end portion within an introducer device;

FIG. 27C is a side view of the distal end portion of the curved shaft ofFIG. 27B in the absence of the introducer device;

FIG. 28A is a side view of the distal end portion of an electrosurgical probe showing an active electrode having an apical spike and an equatorial cusp;

FIG. 28B is a cross-sectional view of the distal end portion of the electrosurgical probe ofFIG. 28A;

FIG. 29 is a side view of the distal end portion a shaft of an electrosurgical probe, indicating the position of a first curve and a second curve in relation to the head of the active electrode;

FIG. 30A shows the distal end portion of the shaft of an electrosurgical probe extended distally from an introducer needle;

FIG. 30B illustrates the position of the active electrode in relation to the inner wall of the introducer needle upon retraction of the active electrode within the introducer needle;

FIGS. 31A,31B show a side view and an end view, respectively, of a curved shaft of an electrosurgical probe, in relation to an introducer needle;

FIG. 32A shows the proximal end portion of the shaft of an electrosurgical probe, wherein the shaft includes a plurality of depth markings;

FIG. 32B shows the proximal end portion of the shaft of an electrosurgical probe, wherein the shaft includes a mechanical stop;

FIG. 33 illustrates stages in manufacture of an active electrode of an electrosurgical probe of the present invention;

FIG. 34 schematically represents a series of steps involved in a method of making a probe shaft of the present invention;

FIG. 35 schematically represents a series of steps involved in a method of making an electrosurgical probe of the present invention;

FIG. 36A schematically represents a normal intervertebral disc in relation to the spinal cord;

FIG. 36B schematically represents an intervertebral disc exhibiting a protrusion of the nucleus pulposus and a concomitant distortion of the annulus fibrosus;

FIG. 36C schematically represents an intervertebral disc exhibiting a plurality of fissures within the annulus fibrosus and a concomitant distortion of the annulus fibrosus;

FIG. 36D schematically represents an intervertebral disc exhibiting fragmentation of the nucleus pulposus and a concomitant distortion of the annulus fibrosus;

FIG. 37 schematically represents translation of a curved shaft of an electrosurgical probe within the nucleus pulposus for treatment of an intervertebral disc;

FIG. 38 shows a shaft of an electrosurgical probe within an intervertebral disc, wherein the shaft distal end is targeted to a specific site within the disc;

FIG. 39 schematically represents a series of steps involved in a method of ablating disc tissue according to the present invention;

FIG. 40 schematically represents a series of steps involved in a method of guiding an electrosurgical probe to a target site within an intervertebral disc for ablation of targeted disc tissue, according to another embodiment of the invention;

FIG. 41 shows treatment of an intervertebral disc using an electrosurgical probe and a separately introduced ancillary device, according to another embodiment of the invention;

FIG. 42 is a side view of an electrosurgical probe having a tracking device;

FIG. 43A shows a steerable electrosurgical probe wherein the shaft of the probe assumes a substantially linear configuration;

FIG. 43B shows the steerable electrosurgical probe ofFIG. 44A, wherein the shaft distal end of the probe adopts a bent configuration; and

FIG. 44 shows a steerable electrosurgical probe and an ancillary device inserted within the nucleus pulposus of an intervertebral disc.

DESCRIPTION OF SPECIFIC EMBODIMENTS

The present invention provides systems and methods for selectively applying electrical energy to a target location within or on a patient's body, particularly including support tissue or other body structures in the spine. These procedures include treating interspinous tissue, degenerative discs, laminectomy/discectomy procedures for treating herniated discs, decompressive laminectomy for stenosis in the lumbosacral and cervical spine, localized tears or fissures in the annulus, nucleotomy, disc fusion procedures, medial facetectomy, posterior lumbosacral and cervical spine fusions, treatment of scoliosis associated with vertebral disease, foraminotomies to remove the roof of the intervertebral foramina to relieve nerve root compression and anterior cervical and lumbar discectomies. These procedures may be performed through open procedures, or using minimally invasive techniques, such as thoracoscopy, arthroscopy, laparascopy or the like.

The present invention involves techniques for treating disc abnormalities with RF energy. In some embodiments, RF energy is used to ablate, debulk and/or stiffen the tissue structure of the disc to reduce the volume of the disc, thereby relieving neck and back pain. In one aspect of the invention, spinal disc tissue is volumetrically removed or ablated to form holes, channels, divots or other spaces within the disc. In this procedure, a high frequency voltage difference is applied between one or more active electrode(s) and one or more return electrode(s) to develop high electric field intensities in the vicinity of the target tissue. The high electric field intensities adjacent the active electrode(s) lead to electric field induced molecular breakdown of target tissue through molecular dissociation (rather than thermal evaporation or carbonization). Applicant believes that the tissue structure is volumetrically removed through molecular disintegration of larger organic molecules into smaller molecules and/or atoms, such as hydrogen, oxygen, oxides of carbon, hydrocarbons and nitrogen compounds. This molecular disintegration completely removes the tissue structure, as opposed to dehydrating the tissue material by the removal of liquid within the cells of the tissue and extracellular fluids, as is typically the case with electrosurgical desiccation and vaporization.

The present invention also involves a system and method for treating the interspinous tissue (e.g., tendons, cartilage, synovial tissue in between the vertebrae, and other support tissue within and surrounding the vertebral column). In some embodiments, RF energy is used to heat and shrink the interspinous tissue to stabilize the vertebral column and reduce pain in the back and neck. In one aspect of the invention, an active electrode is positioned adjacent the interspinous tissue and the interspinous tissue is heated, preferably with RF energy, to a sufficient temperature to shrink the interspinous tissue. In a specific embodiment, a high frequency voltage difference is applied between one or more active electrode(s) and one or more return electrode(s) to develop high electric field intensities in the vicinity of the target tissue to controllably heat the target tissue.

The high electric field intensities may be generated by applying a high frequency voltage that is sufficient to vaporize an electrically conductive fluid over at least a portion of the active electrode(s) in the region between the distal tip of the active electrode(s) and the target tissue. The electrically conductive fluid may be a liquid or gas, such as isotonic saline, blood, extracellular or intracellular fluid, delivered to, or already present at, the target site, or a viscous fluid, such as a gel, applied to the target site. Since the vapor layer or vaporized region has a relatively high electrical impedance, it minimizes the current flow into the electrically conductive fluid. This ionization, under the conditions described herein, induces the discharge of energetic electrons and photons from the vapor layer and to the surface of the target tissue A more detailed description of this phenomena, termed Coblation® can be found in commonly assigned U.S. Pat. No. 5,697,882 the complete disclosure of which is incorporated herein by reference.

Applicant believes that the principle mechanism of tissue removal in the Coblation® mechanism of the present invention is energetic electrons or ions that have been energized in a plasma adjacent to the active electron(s). When a liquid is heated enough that atoms vaporize off the surface faster than they recondense, a gas is formed. When the gas is heated enough that the atoms collide with each other and knock their electrons off in the process, an ionized gas or plasma is formed (the so-called “fourth state of matter”). A more complete description of plasma can be found in Plasma Physics, by R. J. Goldston and P. H. Rutherford of the Plasma Physics Laboratory of Princeton University (1995), the complete disclosure of which is incorporated herein by reference. When the density of the vapor layer (or within a bubble formed in the electricity conducting liquid) becomes sufficiently low (i.e., less than approximately 10²⁰atoms/cm³for aqueous solutions), the electron mean free path increases to enable subsequently injected electrons to cause impact ionization within these regions of low density (i.e., vapor layers or bubbles). Once the isotonic particles in the plasma layer have sufficient energy, they accelerate towards the target tissue. Energy evolved by the energetic electrons (e.g., 3.5 eV to 5 eV) can subsequently bombard a molecule and break its bonds, dissociating a molecule into free radicals, which then combine into final gaseous or liquid species.

Plasmas may be formed by heating a gas and ionizing the gas by driving an electric current through it, or by shining radio waves into the gas. Generally, these methods of plasma formation give energy to free electrons in the plasma directly, and then electron-atom collisions liberate more electrons, and the process cascades until the desired degree of ionization is achieved. Often, the electrons carry the electrical current or absorb the radio waves and, therefore, are hotter than the ions. Thus, in applicant's invention, the electrons, which are carried away from the tissue towards the return electrode, carry most of the plasma's heat with them, allowing the ions to break apart the tissue molecules in a substantially non-thermal manner.

In some embodiments, the present invention applies high frequency (RF) electrical energy in an electrically conducting media environment to shrink or remove (i.e., resect, cut, or ablate) a tissue structure and to seal transected vessels within the region of the target tissue. The present invention may also be useful for sealing larger arterial vessels, e.g., on the order of about 1 mm in diameter. In some embodiments, a high frequency power supply is provided having an ablation mode, wherein a first voltage is applied to an active electrode sufficient to effect molecular dissociation or disintegration of the tissue, and a coagulation mode, wherein a second, lower voltage is applied to an active electrode (either the same or a different electrode) sufficient to heat, shrink, and/or achieve hemostasis of severed vessels within the tissue. In other embodiments, an electrosurgical instrument is provided having one or more coagulation electrode(s) configured for sealing a severed vessel, such as an arterial vessel, and one or more active electrodes configured for either contracting the collagen fibers within the tissue or removing (ablating) the tissue, e.g., by applying sufficient energy to the tissue to effect molecular dissociation. In the latter embodiments, the coagulation electrode(s) may be configured such that a single voltage can be applied to coagulate with the coagulation electrode(s), and to ablate or shrink with the active electrode(s). In other embodiments, the power supply is combined with the coagulation instrument such that the coagulation electrode is used when the power supply is in the coagulation mode (low voltage), and the active electrode(s) are used when the power supply is in the ablation mode (higher voltage).

In one method of the present invention, one or more active electrodes are brought into close proximity to tissue at a target site, and the power supply is activated in the ablation mode such that sufficient voltage is applied between the active electrodes and the return electrode to volumetrically remove the tissue through molecular dissociation, as described below. During this process, vessels within the tissue will be severed. Smaller vessels will be automatically sealed with the system and method of the present invention. Larger vessels, and those with a higher flow rate, such as arterial vessels, may not be automatically sealed in the ablation mode. In these cases, the severed vessels may be sealed by activating a control (e.g., a foot pedal) to reduce the voltage of the power supply into the coagulation mode. In this mode, the active electrodes may be pressed against the severed vessel to provide sealing and/or coagulation of the vessel. Alternatively, a coagulation electrode located on the same or a different instrument may be pressed against the severed vessel. Once the vessel is adequately sealed, the surgeon activates a control (e.g., another foot pedal) to increase the voltage of the power supply back into the ablation mode.

In another aspect, the present invention may be used to shrink or contract collagen connective tissue which supports the vertebral column or connective tissue within the disc. In these procedures, the RF energy heats the tissue directly by virtue of the electrical current flow therethrough, and/or indirectly through the exposure of the tissue to fluid heated by RF energy, to elevate the tissue temperature from normal body temperature (e.g., 37° C.) to temperatures in the range of 45° C. to 90° C., preferably in the range from about 60° C. to 70° C. Thermal shrinkage of collagen fibers occurs within a small temperature range which, for mammalian collagens is in the range from 60° C. to 70° C. (Deak, G., et al., “The Thermal Shrinkage Process of Collagen Fibres as Revealed by Polarization Optical Analysis of Topoptical Staining Reactions,” Acta Morphological Acad. Sci. of Hungary, Vol., 15(2), pp. 195-208, 1967). Collagen fibers typically undergo thermal shrinkage in the range of 60° C. to about 70° C. Previously reported research has attributed thermal shrinkage of collagen to the cleaving of the internal stabilizing cross-linkages within the collagen matrix (Deak, ibid). It has also been reported that when the collagen temperature is increased above 70° C., the collagen matrix begins to relax again and the shrinkage effect is reversed resulting in no net shrinkage (Allain, J. C., et al., “Isometric Tensions Developed During the Hydrothermal Swelling of Rat Skin,” Connective Tissue Research, Vol. 7, pp 127-133, 1980), the complete disclosure of which is incorporated by reference. Consequently, the controlled heating of tissue to a precise depth is critical to the achievement of therapeutic collagen shrinkage. A more detailed description of collagen shrinkage can be found in U.S. patent application Ser. No. 08/942,580 filed on Oct. 2, 1997, the complete disclosure of which is incorporated by reference.

The preferred depth of heating to effect the shrinkage of collagen in the heated region (i.e., the depth to which the tissue is elevated to temperatures between 60° C. to 70° C.) generally depends on (1) the thickness of the target tissue, (2) the location of nearby structures (e.g., nerves) that should not be exposed to damaging temperatures, and/or (3) the location of the collagen tissue layer within which therapeutic shrinkage is to be effected. The depth of heating is usually in the range from 1.0 mm to 5.0 mm. In some embodiments of the present invention, the tissue is purposely damaged in a thermal heating mode to create necrosed or scarred tissue at the tissue surface. The high frequency voltage in the thermal heating mode is below the threshold of ablation as described above, but sufficient to cause some thermal damage to the tissue immediately surrounding the electrodes without vaporizing or otherwise debulking this tissue in situ. Typically, it is desired to achieve a tissue temperature in the range of about 60° C. to 100° C. to a depth of about 0.2 mm to 5 mm, usually about 1 mm to 2 mm. The voltage required for this thermal damage will partly depend on the electrode configurations, the conductivity of the area immediately surrounding the electrodes, the time period in which the voltage is applied and the depth of tissue damage desired. With the electrode configurations described in this application (e.g., FIGS.15A-15D), the voltage level for thermal heating will usually be in the range of about 20 volts rms to 300 volts rms, preferably about 60 volts rms to 200 volts rms. The peak-to-peak voltages for thermal heating with a square wave form having a crest factor of about 2 are typically in the range of about 40 volts peak-to-peak to 600 volts peak-to-peak, preferably about 120 volts peak-to-peak to 400 volts peak-to-peak. In some embodiments, capacitors or other electrical elements may be used to increase the crest factor up to 10. The higher the voltage is within this range, the less time required. If the voltage is too high, however, the surface tissue may be vaporized, debulked or ablated, which is generally undesirable.

In yet another embodiment, the present invention may be used for treating degenerative discs with fissures or tears. In these embodiments, the active and return electrode(s) are positioned in or around the inner wall of the disc annulus such that the active electrode is adjacent to the fissure. High frequency voltage is applied between the active and return electrodes to heat the fissure and shrink the collagen fibers and create a seal or weld within the inner wall, thereby helping to close the fissure in the annulus. In these embodiments, the return electrode will typically be positioned proximally from the active electrode(s) on the instrument shaft, and an electrically conductive fluid will be applied to the target site to create the necessary current path between the active and return electrodes. In alternative embodiments, the disc tissue may complete this electrically conductive path.

The present invention is also useful for removing or ablating tissue around nerves, such as spinal, peripheral or cranial nerves. One of the significant drawbacks with the prior art shavers or microdebriders, conventional electrosurgical devices and lasers is that these devices do not differentiate between the target tissue and the surrounding nerves or bone. Therefore, the surgeon must be extremely careful during these procedures to avoid damage to the bone or nerves within and around the target site. In the present invention, the Coblation® process for removing tissue results in extremely small depths of collateral tissue damage as discussed above. This allows the surgeon to remove tissue close to a nerve without causing collateral damage to the nerve fibers.

In addition to the generally precise nature of the novel mechanisms of the present invention, applicant has discovered an additional method of ensuring that adjacent nerves are not damaged during tissue removal. According to the present invention, systems and methods are provided for distinguishing between the fatty tissue immediately surrounding nerve fibers and the normal tissue that is to be removed during the procedure. Peripheral nerves usually comprise a connective tissue sheath, or epineurium, enclosing the bundles of nerve fibers, each bundle being surrounded by its own sheath of connective tissue (the perineurium) to protect these nerve fibers. The outer protective tissue sheath or epineurium typically comprises a fatty tissue (e.g., adipose tissue) having substantially different electrical properties than the normal target tissue, such as the turbinates, polyps, mucus tissue or the like, that are, for example, removed from the nose during sinus procedures. The system of the present invention measures the electrical properties of the tissue at the tip of the probe with one or more active electrode(s). These electrical properties may include electrical conductivity at one, several or a range of frequencies (e.g., in the range from 1 kHz to 100 MHz), dielectric constant, capacitance or combinations of these. In this embodiment, an audible signal may be produced when the sensing electrode(s) at the tip of the probe detects the fatty tissue surrounding a nerve, or direct feedback control can be provided to only supply power to the active electrode(s) either individually or to the complete array of electrodes, if and when the tissue encountered at the tip or working end of the probe is normal tissue based on the measured electrical properties.

In one embodiment, the current limiting elements (discussed in detail above) are configured such that the active electrodes will shut down or turn off when the electrical impedance reaches a threshold level. When this threshold level is set to the impedance of the fatty tissue surrounding nerves, the active electrodes will shut off whenever they come in contact with, or in close proximity to, nerves. Meanwhile, the other active electrodes, which are in contact with or in close proximity to tissue, will continue to conduct electric current to the return electrode. This selective ablation or removal of lower impedance tissue in combination with the Coblation® mechanism of the present invention allows the surgeon to precisely remove tissue around nerves or bone. Applicant has found that the present invention is capable of volumetrically removing tissue closely adjacent to nerves without impairment the function of the nerves, and without significantly damaging the tissue of the epineurium. One of the significant drawbacks with the prior art microdebriders, conventional electrosurgical devices and lasers is that these devices do not differentiate between the target tissue and the surrounding nerves or bone. Therefore, the surgeon must be extremely careful during these procedures to avoid damage to the bone or nerves within and around the nasal cavity. In the present invention, the Coblation® process for removing tissue results in extremely small depths of collateral tissue damage as discussed above. This allows the surgeon to remove tissue close to a nerve without causing collateral damage to the nerve fibers.

In addition to the above, applicant has discovered that the Coblation® mechanism of the present invention can be manipulated to ablate or remove certain tissue structures, while having little effect on other tissue structures. As discussed above, the present invention uses a technique of vaporizing electrically conductive fluid to form a plasma layer or pocket around the active electrode(s), and then inducing the discharge of energy from this plasma or vapor layer to break the molecular bonds of the tissue structure. Based on initial experiments, applicants believe that the free electrons within the ionized vapor layer are accelerated in the high electric fields near the electrode tip(s). When the density of the vapor layer (or within a bubble formed in the electrically conducting liquid) becomes sufficiently low (i.e., less than approximately 10²⁰atoms/cm³for aqueous solutions), the electron mean free path increases to enable subsequently injected electrons to cause impact ionization within these regions of low density (i.e., vapor layers or bubbles). Energy evolved by the energetic electrons (e.g., 4 eV to 5 eV) can subsequently bombard a molecule and break its bonds, dissociating a molecule into free radicals, which then combine into final gaseous or liquid species.

The energy evolved by the energetic electrons may be varied by adjusting a variety of factors, such as: the number of active electrodes; electrode size and spacing; electrode surface area; asperities and sharp edges on the electrode surfaces; electrode materials; applied voltage and power; current limiting means, such as inductors; electrical conductivity of the fluid in contact with the electrodes; density of the fluid; and other factors. Accordingly, these factors can be manipulated to control the energy level of the excited electrons. Since different tissue structures have different molecular bonds, the present invention can be configured to break the molecular bonds of certain tissue, while having too low an energy to break the molecular bonds of other tissue. For example, fatty tissue, (e.g., adipose) tissue has double bonds that require a substantially higher energy level than 4 eV to 5 eV to break (typically on the order of about 8 eV). Accordingly, the present invention in its current configuration generally does not ablate or remove such fatty tissue. However, the present invention may be used to effectively ablate cells to release the inner fat content in a liquid form. Of course, factors may be changed such that these double bonds can also be broken in a similar fashion as the single bonds (e.g., increasing voltage or changing the electrode configuration to increase the current density at the electrode tips). A more complete description of this phenomena can be found in co-pending U.S. patent application Ser. No. 09/032,375, filed Feb. 27, 1998, the complete disclosure of which is incorporated herein by reference.

In yet other embodiments, the present invention provides systems, apparatus and methods for selectively removing tumors, e.g., facial tumors, or other undesirable body structures while minimizing the spread of viable cells from the tumor. Conventional techniques for removing such tumors generally result in the production of smoke in the surgical setting, termed an electrosurgical or laser plume, which can spread intact, viable bacterial or viral particles from the tumor or lesion to the surgical team or to other portions of the patient's body. This potential spread of viable cells or particles has resulted in increased concerns over the proliferation of certain debilitating and fatal diseases, such as hepatitis, herpes, HIV and papillomavirus. In the present invention, high frequency voltage is applied between the active electrode(s) and one or more return electrode(s) to volumetrically remove at least a portion of the tissue cells in the tumor through the dissociation or disintegration of organic molecules into non-viable atoms and molecules. Specifically, the present invention converts the solid tissue cells into non-condensable gases that are no longer intact or viable, and thus, not capable of spreading viable tumor particles to other portions of the patient's brain or to the surgical staff. The high frequency voltage is preferably selected to effect controlled removal of these tissue cells while minimizing substantial tissue necrosis to surrounding or underlying tissue. A more complete description of this phenomena can be found in co-pending U.S. patent application Ser. No. 09/109,219, filed Jun. 30, 1998, the complete disclosure of which is incorporated herein by reference.

The electrosurgical probe or catheter of the present invention can comprise a shaft or a handpiece having a proximal end and a distal end which supports one or more active electrode(s). The shaft or handpiece may assume a wide variety of configurations, with the primary purpose being to mechanically support the active electrode and permit the treating physician to manipulate the electrode from a proximal end of the shaft. The shaft may be rigid or flexible, with flexible shafts optionally being combined with a generally rigid external tube for mechanical support. Flexible shafts may be combined with pull wires, shape memory actuators, and other known mechanisms for effecting selective deflection of the distal end of the shaft to facilitate positioning of the electrode array. The shaft will usually include a plurality of wires or other conductive elements running axially therethrough to permit connection of the electrode array to a connector at the proximal end of the shaft.

For endoscopic procedures within the spine, the shaft will have a suitable diameter and length to allow the surgeon to reach the target site (e.g., a disc or vertebra) by delivering the shaft through the thoracic cavity, the abdomen or the like. Thus, the shaft will usually have a length in the range of about 5.0 cm to 30.0 cm, and a diameter in the range of about 0.2 mm to about 20 mm. Alternatively, the shaft may be delivered directly through the patient's back in a posterior approach, which would considerably reduce the required length of the shaft. In any of these embodiments, the shaft may also be introduced through rigid or flexible endoscopes. Alternatively, the shaft may be a flexible catheter that is introduced through a percutaneous penetration in the patient. Specific shaft designs will be described in detail in connection with the figures hereinafter.

In an alternative embodiment, the probe may comprise a long, thin needle (e.g., on the order of about 1 mm in diameter or less) that can be percutaneously introduced through the patient's back directly into the spine. The needle will include one or more active electrode(s) for applying electrical energy to tissues within the spine. The needle may include one or more return electrode(s), or the return electrode may be positioned on the patient's back, as a dispersive pad. In either embodiment, sufficient electrical energy is applied through the needle to the active electrode(s) to either shrink the collagen fibers within the spinal disc, to ablate tissue within the disc, or to shrink support fibers surrounding the vertebrae.

The electrosurgical instrument may also be a catheter that is delivered percutaneously and/or endoluminally into the patient by insertion through a conventional or specialized guide catheter, or the invention may include a catheter having an active electrode or electrode array integral with its distal end. The catheter shaft may be rigid or flexible, with flexible shafts optionally being combined with a generally rigid external tube for mechanical support. Flexible shafts may be combined with pull wires, shape memory actuators, and other known mechanisms for effecting selective deflection of the distal end of the shaft to facilitate positioning of the electrode or electrode array. The catheter shaft will usually include a plurality of wires or other conductive elements running axially therethrough to permit connection of the electrode or electrode array and the return electrode to a connector at the proximal end of the catheter shaft. The catheter shaft may include a guide wire for guiding the catheter to the target site, or the catheter may comprise a steerable guide catheter. The catheter may also include a substantially rigid distal end portion to increase the torque control of the distal end portion as the catheter is advanced further into the patient's body. Specific shaft designs will be described in detail in connection with the figures hereinafter.

The active electrode(s) are preferably supported within or by an inorganic insulating support positioned near the distal end of the instrument shaft. The return electrode may be located on the instrument shaft, on another instrument or on the external surface of the patient (i.e., a dispersive pad). The close proximity of nerves and other sensitive tissue in and around the spinal cord, however, makes a bipolar design more preferable because this minimizes the current flow through non-target tissue and surrounding nerves. Accordingly, the return electrode is preferably either integrated with the instrument body, or another instrument located in close proximity thereto. The proximal end of the instrument(s) will include the appropriate electrical connections for coupling the return electrode(s) and the active electrode(s) to a high frequency power supply, such as an electrosurgical generator.

In some embodiments, the active electrode(s) have an active portion or surface with surface geometries shaped to promote the electric field intensity and associated current density along the leading edges of the electrodes. Suitable surface geometries may be obtained by creating electrode shapes that include preferential sharp edges, or by creating asperities or other surface roughness on the active surface(s) of the electrodes. Electrode shapes according to the present invention can include the use of formed wire (e.g., by drawing round wire through a shaping die) to form electrodes with a variety of cross-sectional shapes, such as square, rectangular, L or V shaped, or the like. Electrode edges may also be created by removing a portion of the elongate metal electrode to reshape the cross-section. For example, material can be ground along the length of a round or hollow wire electrode to form D or C shaped wires, respectively, with edges facing in the cutting direction. Alternatively, material can be removed at closely spaced intervals along the electrode length to form transverse grooves, slots, threads or the like along the electrodes.

Additionally or alternatively, the active electrode surface(s) may be modified through chemical, electrochemical or abrasive methods to create a multiplicity of surface asperities on the electrode surface. These surface asperities will promote high electric field intensities between the active electrode surface(s) and the target tissue to facilitate ablation or cutting of the tissue. For example, surface asperities may be created by etching the active electrodes with etchants having a pH less than 7.0 or by using a high velocity stream of abrasive particles (e.g., grit blasting) to create asperities on the surface of an elongated electrode. A more detailed description of such electrode configuration can be found in U.S. Pat. No. 5,843,019, the complete disclosure of which is incorporated herein by reference.

The return electrode is typically spaced proximally from the active electrode(s) a suitable distance to avoid electrical shorting between the active and return electrodes in the presence of electrically conductive fluid. In most of the embodiments described herein, the distal edge of the exposed surface of the return electrode is spaced about0.5 mm to 25 mm from the proximal edge of the exposed surface of the active electrode(s), preferably about 1.0 mm to 5.0 mm. Of course, this distance may vary with different voltage ranges, conductive fluids, and depending on the proximity of tissue structures to active and return electrodes. The return electrode will typically have an exposed length in the range of about 1 mm to 20 mm.

The current flow path between the active electrodes and the return electrode(s) may be generated by submerging the tissue site in an electrical conducting fluid (e.g., within a viscous fluid, such as an electrically conductive gel) or by directing an electrically conductive fluid along a fluid path to the target site (i.e., a liquid, such as isotonic saline, hypotonic saline or a gas, such as argon). The conductive gel may also be delivered to the target site to achieve a slower more controlled delivery rate of conductive fluid. In addition, the viscous nature of the gel may allow the surgeon to more easily contain the gel around the target site (e.g., rather than attempting to contain isotonic saline). A more complete description of an exemplary method of directing electrically conductive fluid between the active and return electrodes is described in U.S. Pat. No. 5,697,281, previously incorporated herein by reference. Alternatively, the body's natural conductive fluids, such as blood or extracellular saline, may be sufficient to establish a conductive path between the return electrode(s) and the active electrode(s) and to provide the conditions for establishing a vapor layer, as described above. However, conductive fluid that is introduced into the patient is generally preferred over blood because blood will tend to coagulate at certain temperatures. In addition, the patient's blood may not have sufficient electrical conductivity to adequately form a plasma in some applications. Advantageously, a liquid electrically conductive fluid (e.g., isotonic saline) may be used to concurrently “bathe” the target tissue surface to provide an additional means for removing any tissue, and to cool the region of the target tissue ablated in the previous moment.

The power supply, or generator, may include a fluid interlock for interrupting power to the active electrode(s) when there is insufficient conductive fluid around the active electrode(s). This ensures that the instrument will not be activated when conductive fluid is not present, minimizing the tissue damage that may otherwise occur. A more complete description of such a fluid interlock can be found in commonly assigned, co-pending U.S. applicant Ser. No. 09/058,336, filed Apr. 10, 1998, the complete disclosure of which is incorporated herein by reference.

In some procedures, it may also be necessary to retrieve or aspirate the electrically conductive fluid and/or the non-condensable gaseous products of ablation. In addition, it may be desirable to aspirate small pieces of tissue or other body structures that are not completely disintegrated by the high frequency energy, or other fluids at the target site, such as blood, mucus, the gaseous products of ablation, etc. Accordingly, the system of the present invention may include one or more suction lumen(s) in the instrument, or on another instrument, coupled to a suitable vacuum source for aspirating fluids from the target site. In addition, the invention may include one or more aspiration electrode(s) coupled to the distal end of the suction lumen for ablating, or at least reducing the volume of, non-ablated tissue fragments that are aspirated into the lumen. The aspiration electrode(s) function mainly to inhibit clogging of the lumen that may otherwise occur as larger tissue fragments are drawn therein. The aspiration electron(s) may be different from the ablation active electrode(s), or the same electrode(s) may serve both functions. A more complete description of instruments incorporating aspiration electrode(s) can be found in commonly assigned, co-pending U.S. patent application Ser. No. 09/010,382 filed Jan. 21, 1998, the complete disclosure of which is incorporated herein by reference.

As an alternative or in addition to suction, it may be desirable to contain the excess electrically conductive fluid, tissue fragments and/or gaseous products of ablation at or near the target site with a containment apparatus, such as a basket, retractable sheath, or the like. This embodiment has the advantage of ensuring that the conductive fluid, tissue fragments or ablation products do not flow through the patient's vasculature or into other portions of the body. In addition, it may be desirable to limit the amount of suction to limit the undesirable effect suction may have on hemostasis of severed blood vessels.

The present invention may use a single active electrode or an array of active electrodes spaced around the distal surface of a catheter or probe. In the latter embodiment, the electrode array usually includes a plurality of independently current-limited and/or power-controlled active electrodes to apply electrical energy selectively to the target tissue while limiting the unwanted application of electrical energy to the surrounding tissue and environment resulting from power dissipation into surrounding electrically conductive fluids, such as blood, normal saline, and the like. The active electrodes may be independently current-limited by isolating the terminals from each other and connecting each terminal to a separate power source that is isolated from the other active electrodes. Alternatively, the active electrodes may be connected to each other at either the proximal or distal ends of the catheter to form a single wire that couples to a power source.

In one configuration, each individual active electrode in the electrode array is electrically insulated from all other active electrodes in the array within said instrument and is connected to a power source which is isolated from each of the other active electrodes in the array or to circuitry which limits or interrupts current flow to the active electrode when low resistivity material (e.g., blood, electrically conductive saline irrigant or electrically conductive gel) causes a lower impedance path between the return electrode and the individual active electrode. The isolated power sources for each individual active electrode may be separate power supply circuits having internal impedance characteristics which limit power to the associated active electrode when a low impendance return path is encountered. By way of example, the isolated power source may be a user selectable constant current source. In this embodiment, lower impedance paths will automatically result in lower resistive heating levels since the heating is proportional to the square of the operating current times the impedance. Alternatively, a single power source may be connected to each of the active electrodes through independently actuatable switches, or by independent current limiting elements, such as inductors, capacitors, resistors and/or combinations thereof. The current limiting elements may be provided in the instrument, connectors, cable, controller, or along the conductive path from the controller to the distal tip of the instrument. Alternatively, the resistance and/or capacitance may occur on the surface of the active electrode(s) due to oxide layers which form selected active electrodes (e.g., titanium or a resistive coating on the surface of metal, such as platinum).

The tip region of the instrument may comprise many independent active electrodes designed to deliver electrical energy in the vicinity of the tip. The selective application of electrical energy to the conductive fluid is achieved by connecting each individual active electrode and the return electrode to a power source having independently controlled or current limited channels. The return electrode(s) may comprise a single tubular member of conductive material proximal to the electrode array at the tip which also serves as a conduit for the supply of the electrically conductive fluid between the active and return electrodes. Alternatively, the instrument may comprise an array of return electrodes at the distal tip of the instrument (together with the active electrodes) to maintain the electric current at the tip. The application of high frequency voltage between the return electrode(s) and the electrode array results in the generation of high electric field intensities at the distal tips of the active electrodes with conduction of high frequency current from each individual active electrode to the return electrode. The current flow from each individual active electrode to the return electrode(s) is controlled by either active or passive means, or a combination thereof, to deliver electrical energy to the surrounding conductive fluid while minimizing energy delivery to surrounding (non-target) tissue.

The application of a high frequency voltage between the return electrode(s) and the active electrode(s) for appropriate time intervals effects shrinking, cutting, removing, ablating, shaping, contracting or otherwise modifying the target tissue. In some embodiments of the present invention, the tissue volume over which energy is dissipated (i.e., a high current density exists) may be more precisely controlled, for example, by the use of a multiplicity of small active electrodes whose effective diameters or principle dimensions range from about 10 mm to 0.01 mm, preferably from about 2 mm to 0.05 mm, and more preferably from about 1 mm to 0.1 mm. In this embodiment, electrode areas for both circular and non-circular terminals will have a contact area (per active electrode) below 50 mm²for electrode arrays and as large as 75 mm²for single electrode embodiments. In multiple electrode array embodiments, the contact area of each active electrode is typically in the range from 0.0001 mm²to 1 mm², and more preferably from 0.001 mm²to 0.5 mm². The circumscribed area of the electrode array or active electrode is in the range from 0.25 mm²to 75 mm², preferably from 0.5 mm²to 40 mm². In multiple electrode embodiments, the array will usually include at least two isolated active electrodes, often at least five active electrodes, often greater than 10 active electrodes and even 50 or more active electrodes, disposed over the distal contact surfaces on the shaft. The use of small diameter active electrodes increases the electric field intensity and reduces the extent or depth of tissue heating as a consequence of the divergence of current flux lines which emanate from the exposed surface of each active electrode.

The area of the tissue treatment surface can vary widely, and the tissue treatment surface can assume a variety of geometries, with particular areas and geometries being selected for specific applications. The geometries can be planar, concave, convex, hemispherical, conical, linear “inline” array or virtually any other regular or irregular shape. Most commonly, the active electrode(s) or active electrode(s) will be formed at the distal tip of the electrosurgical instrument shaft, frequently being planar, disk-shaped, or hemispherical surfaces for use in reshaping procedures or being linear arrays for use in cutting. Alternatively or additionally, the active electrode(s) may be formed on lateral surfaces of the electrosurgical instrument shaft (e.g., in the manner of a spatula), facilitating access to certain body structures in endoscopic procedures.

It should be clearly understood that the invention is not limited to electrically isolated active electrodes, or even to a plurality of active electrodes. For example, the array of active electrodes may be connected to a single lead that extends through the catheter shaft to a power source of high frequency current. Alternatively, the instrument may incorporate a single electrode that extends directly through the catheter shaft or is connected to a single lead that extends to the power source. The active electrode(s) may have ball shapes (e.g., for tissue vaporization and desiccation), twizzle shapes (for vaporization and needle-like cutting), spring shapes (for rapid tissue debulking and desiccation), twisted metal shapes, annular or solid tube shapes or the like. Alternatively, the electrode(s) may comprise a plurality of filaments, rigid or flexible brush electrode(s) (for debulking a tumor, such as a fibroid, bladder tumor or a prostate adenoma), side-effect brush electrode(s) on a lateral surface of the shaft, coiled electrode(s) or the like.

In some embodiments, the electrode support and the fluid outlet may be recessed from an outer surface of the instrument or handpiece to confine the electrically conductive fluid to the region immediately surrounding the electrode support. In addition, the shaft may be shaped so as to form a cavity around the electrode support and the fluid outlet. This helps to assure that the electrically conductive fluid will remain in contact with the active electrode(s) and the return electrode(s) to maintain the conductive path therebetween. In addition, this will help to maintain a vapor layer and subsequent plasma layer between the active electrode(s) and the tissue at the treatment site throughout the procedure, which reduces the thermal damage that might otherwise occur if the vapor layer were extinguished due to a lack of conductive fluid. Provision of the electrically conductive fluid around the target site also helps to maintain the tissue temperature at desired levels.

In other embodiments, the active electrodes are spaced from the tissue a sufficient distance to minimize or avoid contact between the tissue and the vapor layer formed around the active electrodes. In these embodiments, contact between the heated electrons in the vapor layer and the tissue is minimized as these electrons travel from the vapor layer back through the conductive fluid to the return electrode. The ions within the plasma, however, will have sufficient energy, under certain conditions such as higher voltage levels, to accelerate beyond the vapor layer to the tissue. Thus, the tissue bonds are dissociated or broken as in previous embodiments, while minimizing the electron flow, and thus the thermal energy, in contact with the tissue.

The electrically conductive fluid should have a threshold conductivity to provide a suitable conductive path between the return electrode and the active electrode(s). The electrical conductivity of the fluid (in units of millisiemens per centimeter or mS/cm) will usually be greater than 0.2 mS/cm, preferably will be greater than 2 mS/cm and more preferably greater than 10 mS/cm. In an exemplary embodiment, the electrically conductive fluid is isotonic saline, which has a conductivity of about 17 mS/cm. Applicant has found that a more conductive fluid, or one with a higher ionic concentration, will usually provide a more aggressive ablation rate. For example, a saline solution with higher levels of sodium chloride than conventional saline (which is on the order of about 0.9% sodium chloride) e.g., on the order of greater than 1% or between about 3% and 20%, may be desirable. Alternatively, the invention may be used with different types of conductive fluids that increase the power of the plasma layer by, for example, increasing the quantity of ions in the plasma, or by providing ions that have higher energy levels than sodium ions. For example, the present invention may be used with elements other than sodium, such as potassium, magnesium, calcium and other metals near the left end of the periodic chart. In addition, other electronegative elements may be used in place of chlorine, such as fluorine.

The voltage difference applied between applied between the return electrode(s) and the active electrode(s) will be at high or radio frequency, typically between about 5 kHz and 20 MHz, usually being between about 30 kHz and 2.5 MHz, preferably being between about 50 kHz and 500 kHz, often less than 350 kHz , and often between about 100 kHz and 200 kHz. In some applications, applicant has found that a frequency of about 100 kHz is useful because the tissue impedance is much greater at this frequency. In other applications, such as procedures in or around the heart or head and neck, higher frequencies may be desirable (e.g., 400-600 kHz) to minimize low frequency current flow into the heart or the nerves of the head and neck. The RMS (root mean square) voltage applied will usually be in the range from about 5 volts to 1000 volts, preferably being in the range from about 10 volts to 500 volts, often between about 150 volts to 400 volts depending on the active electrode size, the operating frequency and the operation mode of the particular procedure or desired effect on the tissue (i.e., contraction, coagulation, cutting or ablation). Typically, the peak-to-peak voltage for ablation or cutting with a square wave form will be in the range of 10 volts to 2000 volts and preferably in the range of 100 volts to 1800 volts and more preferably in the range of about 300 volts to 1500 volts, often in the range of about 300 volts to 800 volts peak to peak (again, depending on the electrode size, number of electrons, the operating frequency and the operation mode). Lower peak-to-peak voltages will be used for tissue coagulation, thermal heating of tissue, or collagen contraction and will typically be in the range from 50 to 1500, preferably 100 to 1000 and more preferably 120 to 400 volts peak-to-peak (again, these values are computed using a square wave form). Higher peak-to-peak voltages, e.g., greater than about 800 volts peak-to-peak, may be desirable for ablation of harder material, such as bone, depending on other factors, such as the electrode geometries and the composition of the conductive fluid.

As discussed above, the voltage is usually delivered in a series of voltage pulses or alternating current of time varying voltage amplitude with a sufficiently high frequency (e.g., on the order of 5 kHz to 20 MHz) such that the voltage is effectively applied continuously (as compared with e.g., lasers claiming small depths of necrosis, which are generally pulsed about 10 Hz to 20 Hz). In addition, the duty cycle (i.e., cumulative time in any one-second interval that energy is applied) is on the order of about 50% for the present invention, as compared with pulsed lasers which typically have a duty cycle of about 0.0001%.

The preferred power source of the present invention delivers a high frequency current selectable to generate average power levels ranging from several milliwatts to tens of watts per electrode, depending on the volume of target tissue being treated, and/or the maximum allowed temperature selected for the instrument tip. The power source allows the user to select the voltage level according to the specific requirements of a particular neurosurgery procedure, cardiac surgery, arthroscopic surgery, dermatological procedure, ophthalmic procedures, open surgery or other endoscopic surgery procedure. For cardiac procedures and potentially for neurosurgery, the power source may have an additional filter, for filtering leakage voltages at frequencies below 100 kHz, particularly voltages around 60 kHz. Alternatively, a power source having a higher operating frequency, e.g., 300 kHz to 600 kHz may be used in certain procedures in which stray low frequency currents may be problematic. A description of one suitable power source can be found in co-pending patent application Ser. Nos. 09/058,571 and 09/058,336, filed Apr. 10, 1998, the complete disclosure of both applications are incorporated herein by reference for all purposes.

The power source may be current limited or otherwise controlled so that undesired heating of the target tissue or surrounding (non-target) tissue does not occur. In a presently preferred embodiment of the present invention, current limiting inductors are placed in series with each independent active electrode, where the inductance of the inductor is in the range of 10 uH to 50,000 uH, depending on the electrical properties of the target tissue, the desired tissue heating rate and the operating frequency. Alternatively, capacitor-inductor (LC) circuit structures may be employed, as described previously in U.S. Pat. No. 5,697,909, the complete disclosure of which is incorporated herein by reference. Additionally, current limiting resistors may be selected. Preferably, these resistors will have a large positive temperature coefficient of resistance so that, as the current level begins to rise for any individual active electrode in contact with a low resistance medium (e.g., saline irrigant or blood), the resistance of the current limiting resistor increases significantly, thereby minimizing the power delivery from said active electrode into the low resistance medium (e.g., saline irrigant or blood).

Referring toFIG. 1, anexemplary electrosurgical system11 for treatment of tissue in the spine will now be described in detail.Electrosurgical system11 generally comprises an electrosurgical handpiece or probe10 connected to apower supply28 for providing high frequency voltage to a target site, and afluid source21 for supplying electricallyconductive fluid50 to probe10. In addition,electrosurgical system11 may include an endoscope (not shown) with a fiber optic head light for viewing the surgical site. The endoscope may be integral withprobe10, or it may be part of a separate instrument. Thesystem11 may also include a vacuum source (not shown) for coupling to a suction lumen or tube211 (seeFIG. 4) in theprobe10 for aspirating the target site.

As shown, probe10 generally includes a proximal handle19 and anelongate shaft18 having anarray12 ofactive electrodes58 at its distal end. A connectingcable34 has aconnector26 for electrically coupling theactive electrodes58 topower supply28. Theactive electrodes58 are electrically isolated from each other and each ofelectrodes58 is connected to an active or passive control network withinpower supply28 by means of a plurality of individually insulated conductors (not shown). Afluid supply tube15 is connected to afluid tube14 ofprobe10 for supplying electricallyconductive fluid50 to the target site.Fluid supply tube15 may be connected to a suitable pump (not shown), if desired.

Power supply28 has an operator controllablevoltage level adjustment30 to change the applied voltage level, which is observable at avoltage level display32.Power supply28 also includes first, second andthird foot pedals37,38,39 and acable36 which is removably coupled topower supply28. Thefoot pedals37,38,39 allow the surgeon to remotely adjust the energy level applied toactive electrodes58. In an exemplary embodiment,first foot pedal37 is used to place the power supply into the “ablation” mode andsecond foot pedal38places power supply28 into the “sub-ablation” mode (e.g., for coagulation or contraction of tissue). Thethird foot pedal39 allows the user to adjust the voltage level within the “ablation” mode. In the ablation mode, a sufficient voltage is applied to the active electrodes to establish the requisite conditions for molecular dissociation of the tissue (i.e., vaporizing a portion of the electrically conductive fluid, ionizing charged particles within the vapor layer and accelerating these charged particles against the tissue). As discussed above, the requisite voltage level for ablation will vary depending on the number, size, shape and spacing of the electrodes, the distance in which the electrodes extend from the support member, etc. Once the surgeon places the power supply in the “ablation” mode,voltage level adjustment30 orthird foot pedal39 may be used to adjust the voltage level to adjust the degree or aggressiveness of the ablation.

Of course, it will be recognized that the voltage and modality of the power supply may be controlled by other input devices. However, applicant has found that foot pedals are convenient methods of controlling the power supply while manipulating the probe during a surgical procedure.

In the subablation mode, thepower supply28 applies a low enough voltage to the active electrodes to avoid vaporization of the electrically conductive fluid and subsequent molecular dissociation of the tissue. The surgeon may automatically toggle the power supply between the ablation and sub-ablation modes by alternatively stepping onfoot pedals37,38, respectively. In some embodiments, this allows the surgeon to quickly move between coagulation/thermal heating and ablation in situ, without having to remove his/her concentration from the surgical field or without having to request an assistant to switch the power supply. By way of example, as the surgeon is sculpting soft tissue in the ablation mode, the probe typically will simultaneously seal and/or coagulation small severed vessels within the tissue. However, larger vessels, or vessels with high fluid pressures (e.g., arterial vessels) may not be sealed in the ablation mode. Accordingly, the surgeon can simply step onfoot pedal38, automatically lowering the voltage level below the threshold level for ablation, and apply sufficient pressure onto the severed vessel for a sufficient period of time to seal and/or coagulate the vessel. After this is completed, the surgeon may quickly move back into the ablation mode by stepping onfoot pedal37.

Referring now toFIGS. 2 and 3, a representative high frequency power supply for use according to the principles of the present invention will now by described. The high frequency power supply of the present invention is configured to apply a high frequency voltage of about 10 volts RMS to 500 volts RMS between one or more active electrodes (and/or coagulation electrode) and one or more return electrodes. In the exemplary embodiment, the power supply applies about 70 volts RMS to 350 volts RMS in the ablation mode and about 20 volts to 90 volts in a subablation mode, preferably 45 volts to 70 volts in the subablation mode (these values will, of course, vary depending on the probe configuration attached to the power supply and the desired mode of operation).

The preferred power source of the present invention delivers a high frequency current selectable to generate average power levels ranging from several milliwatts to tens of watts per electrode, depending on the volume of target tissue being treated, and/or the maximum allowed temperature selected for the probe tip. The power supply allows the user to select the voltage level according to the specific requirements of a particular procedure, e.g., spinal surgery, arthroscopic surgery, dermatological procedure, ophthalmic procedures, open surgery, or other endoscopic surgery procedure.

As shown inFIG. 2, the power supply generally comprises a radio frequency (RF) power oscillator70 having output connections for coupling via a power output signal71 to the load impedance, which is represented by the electrode assembly when the electrosurgical probe is in use. In the representative embodiment, the RF oscillator operates at about 100 kHz. The RF oscillator is not limited to this frequency and may operate at frequencies of about 300 kHz to 600 kHz. In particular, for cardiac applications, the RF oscillator will preferably operate in the range of about 400 kHz to about 600 kHz. The RF oscillator will generally supply a square wave signal with a crest factor of about 1 to 2. Of course, this signal may be a sine wave signal or other suitable wave signal depending on the application and other factors, such as the voltage applied, the number and geometry of the electrodes, etc. The power output signal71 is designated to incur minimal voltage decrease (i.e., sag) under load. This improves the applied voltage to the active electrodes and the return electrode, which improves the rate of volumetric removal (ablation) of tissue.

Power is supplied to RF oscillator70 by a switching power supply72 coupled between the power line and the RF oscillator rather than a conventional transformer. The switching power supply72 allowspower supply28 to achieve high peak power output without the large size and weight of a bulky transformer. The architecture of the switching power supply also has been designed to reduce electromagnetic noise such that U.S. and foreign EMI requirements are met. This architecture comprises a zero voltage switching or crossing, which causes the transistors to turn ON and OFF when the voltage is zero. Therefore, the electromagnetic noise produced by the transistors switching is vastly reduced. In an exemplary embodiment, the switching power supply72 operates at about 100 kHz.

A controller74 coupled to the operator controls73 (i.e., foot pedals and voltage selector) and display76, is connected to a control input of the switching power supply72 for adjusting the generator output power by supply voltage variation. The controller74 may be a microprocessor or an integrated circuit. The power supply may also include one or more current sensors75 for detecting the output current. The power supply is preferably housed within a metal casing which provides a durable enclosure for the electrical components therein. In addition, the metal casing reduces the electromagnetic noise generated within the power supply because the grounded metal casing functions as a “Faraday shield,” thereby shielding the environment from internal sources of electromagnetic noise.

The power supply generally comprises a main or mother board containing generic electrical components required for many different surgical procedure (e.g., arthroscopy, urology, general surgery, dermatology, neurosurgery, etc.), and a daughter board containing application specific current-limiting circuitry (e.g., inductors, resistors, capacitors and the like). The daughter board is coupled to the mother board by a detachable multi-pin connector to allow convenient conversion of the power supply to, e.g., applications requiring a different current limiting circuit design. For arthroscopy, for example, the daughter board preferably comprises a plurality of inductors of about 200 to 400 microhenries, usually about 300 microhenries, for each of the channels supplying current to the active electrodes102 (see FIG.4).

Alternatively, in one embodiment, current limiting inductors are placed in series with each independent active electrode, where the inductance of the inductor is in the range of 10 uH to 50,000 uH, depending on the electrical properties of the target tissue, the desired tissue heating rate and the operating frequency. Alternatively, capacitor-inductor (LC) circuit structures may be employed, as described previously in co-pending PCT application Ser. No. PCT/US94/05168, the complete disclosure of which is incorporated herein by reference. Additionally, current limiting resistors may be selected. Preferably, these resistors will have a large positive temperature coefficient of resistance so that, as the current level begins to rise for any individual active electrode in contact with a low resistance medium (e.g., saline irrigant or conductive gel), the resistance of the current limiting resistor increases significantly, thereby minimizing the power delivery from said active electrode into the low resistance medium (e.g., saline irrigant or conductive gel). Power output signal may also be coupled to a plurality of current limitingelements96, which are preferably located on the daughter board since the current limiting elements may vary depending on the application. A more complete description of a representative power supply can be found in commonly assigned U.S. patent application Ser. No. 09/058,571, previously incorporated herein by reference.

FIGS. 4-6 illustrate anexemplary electrosurgical probe20 constructed according to the principles of the present invention. As shown inFIG. 4, probe20 generally includes anelongated shaft100 which may be flexible or rigid, ahandle204 coupled to the promixal end ofshaft100 and anelectrode support member102 coupled to the distal end ofshaft100.Shaft100 preferably comprises an electrically conducting material, usually metal, which is selected from the group comprising tungsten, stainless steel alloys, platinum or its alloys, titanium or its alloys, molybdenum or its alloys, and nickel or its alloys. In this embodiment,shaft100 includes an electrically insulatingjacket108, which is typically formed as one or more electrically insulating sheaths or coatings, such as polytetrafluoroethylene, polyimide, and the like. The provision of the electrically insulating jacket over the shaft prevents direct electrical contact between these metal elements and any adjacent body structure or the surgeon. Such direct electrical contact between a body structure (e.g., tendon) and an exposed electrode could result in unwanted heating and necrosis of the structure at the point of contact causing necrosis. Alternatively, the return electrode may comprise an annular band coupled to an insulating shaft and having a connector extending within the shaft to its proximal end.

Handle204 typically comprises a plastic material that is easily molded into a suitable shape for handling by the surgeon. Handle204 defines an inner cavity (not shown) that houses the electrical connections250 (FIG.6), and provides a suitable interface for connection to an electrical connecting cable distal portion22 (seeFIG. 1)Electrode support member102 extends from the distal end of shaft100 (usually about 1 mm to 20 mm), and provides support for a plurality of electrically isolated active electrodes104 (see FIG.5). As shown inFIG. 4, afluid tube233 extends through an opening inhandle204, and includes aconnector235 for connection to a fluid supply source, for supplying electrically conductive fluid to the target site. Depending on the configuration of the distal surface ofshaft100,fluid tube233 may extend through a single lumen (not shown) inshaft100, or it may be coupled to a plurality of lumens (also not shown) that extend throughshaft100 to a plurality of openings at its distal end. In the representative embodiment,tubing239 is a tube that extends along the exterior ofshaft100 to a point just distal of return electrode112 (see FIG.5). In this embodiment, the fluid is directed through anopening237past return electrode112 to theactive electrodes104.Probe20 may also include a valve17 (FIG. 1) or equivalent structure for controlling the flow rate of the electrically conductive fluid to the target site.

As shown inFIG. 4, the distal portion ofshaft100 is preferably bent to improve access to the operative site of the tissue being treated.Electrode support member102 has a substantially planer tissue treatment surface212 (FIG. 5) that is usually at an angle of about 10 degrees to 90 degrees relative to the longitudinal axis ofshaft100, preferably about 30 degrees to 60 degrees and more preferably about 45 degrees. In alternative embodiments, the distal portion ofshaft100 comprises a flexible material which can be deflected relative to the longitudinal axis of the shaft. Such deflection may be selectively induced by mechanical tension of a pull wire, for example, or by a shape memory wire that expands or contracts by externally applied temperature changes. A more complete description of this embodiment can be found in U.S. Pat. No. 5, 697,909, the complete disclosure of which has previously been incorporated herein by reference. Alternatively, theshaft100 of the present invention may be bent by the physician to the appropriate angle using a conventional bending tool or the like.

In the embodiment shown in FIGS4 to6,probe20 includes areturn electrode112 for completing the current path betweenactive electrodes104 and a high frequency power supply28 (see FIG.1). As shown,return electrode112 preferably comprises an exposed portion ofshaft100 shaped as an annular conductive band near the distal end ofshaft100 slightly proximal totissue treatment surface212 ofelectrode support member102, typically about 0.5 mm to 10 mm and more preferably about 1 mm to 10 mm.Return electrode112 orshaft100 is coupled to aconnector258 that extends to the proximal end ofprobe10/20, where it is suitably connected to power supply28 (FIG.1).

As shown inFIG. 4,return electrode112 is not directly connected toactive electrodes104. To complete this current path so thatactive electrodes104 are electrically connected to returnelectrode112, an electrically conductive fluid (e.g., isotonic saline) is caused to flow therebetween. In the representative embodiment, the electrically conductive fluid is delivered throughfluid tube233 to opening237, as described above. Alternatively, the conductive fluid may be delivered by a fluid delivery element (not shown) that is separate fromprobe20. In arthroscopic surgery, for example, the target area of the joint will be flooded with isotonic saline and theprobe90 will be introduced into this flooded target area. Electrically conductive fluid can be continually resupplied to maintain the conduction path betweenreturn electrode112 andactive electrodes104. In other embodiments, the distal portion ofprobe20 may be dipped into a source of electrically conductive fluid, such as a gel or isotonic saline, prior to positioning at the target site. Applicant has found that the surface tension of the fluid and/or the viscous nature of a gel allows the conductive fluid to remain around the active and return electrodes for long enough to complete its function according to the present invention, as described below. Alternatively, the conductive fluid, such as a gel, may be applied directly to the target site.

In alternative embodiments, the fluid path may be formed inprobe90 by, for example, an inner lumen or an annular gap between the return electrode and a tubular support member within shaft100 (see FIGS.8A and8B). This annular gap may be formed near the perimeter of theshaft100 such that the electrically conductive fluid tends to flow radially inward towards the target site, or it may be formed towards the center ofshaft100 so that the fluid flows radially outward. In both of these embodiments, a fluid source (e.g., a bag of fluid elevated above the surgical site or having a pumping device), is coupled to probe90 via a fluid supply tube (not shown) that may or may not have a controllable valve. A more complete description of an electrosurgical probe incorporating one or more fluid lumen(s) can be found in U.S. Pat. No. 5,697,281, the complete disclosure of which has previously been incorporated herein by reference.

Referring toFIG. 5, the electrically isolatedactive electrodes104 are spaced apart overtissue treatment surface212 ofelectrode support member102. The tissue treatment surface and individualactive electrodes104 will usually have dimensions within the ranges set forth above. In the representative embodiment, thetissue treatment surface212 has a circular cross-sectional shape with a diameter in the range of 1 mm to 20 mm. The individualactive electrodes104 preferably extend outward fromtissue treatment surface212 by a distance of about 0.1. mm to 4 mm, usually about 0.2 mm to 2 mm. Applicant has found that this configuration increases the high electric field intensities and associated current densities aroundactive electrodes104 to facilitate the ablation and shrinkage of tissue as described in detail above.

In the embodiment ofFIGS. 4 to6, the probe includes a single,larger opening209 in the center oftissue treatment surface212, and a plurality of active electrodes (e.g., about 3-15) around the perimeter of surface212 (see FIG.5). Alternatively, the probe may include a single, annular, or partially annular, active electrode at the perimeter of the tissue treatment surface. Thecentral opening209 is coupled to a suction lumen (not shown) withinshaft100 and a suction tube211 (FIG. 4) for aspirating tissue, fluids and/or gases from the target site. In this embodiment, the electrically conductive fluid generally flows radially inward pastactive electrodes104 and then back through theopening209. Aspirating the electrically conductive fluid during surgery allows the surgeon to see the target site, and it prevents the fluid from flowing into the patient's body.

Of course, it will be recognized that the distal tip of an electrosurgical probe of the invention,e.g. probe10/20/90, may have a variety of different configurations. For example, the probe may include a plurality ofopenings209 around the outer perimeter of tissue treatment surface212 (see FIG.7B). In this embodiment, theactive electrodes104 extend distally from the center of tissue treatment surfaces212 such that they are located radially inward from opening209. The openings are suitably coupled tofluid tube233 for delivering electrically conductive fluid to the target site, andsuction tube211 for aspirating the fluid after it has completed the conductive path between thereturn electrode112 and theactive electrodes104.

FIG. 6 illustrates theelectrical connectors250 withinhandle204 for couplingactive electrodes104 and return electrode112 to thepower supply28. As shown, a plurality ofwires252 extend throughshaft100 to coupleactive electrodes104 to a plurality ofpins254, which are plugged into aconnector block256 for coupling to a connecting cable distal end22 (FIG.1). Similarly, returnelectrode112 is coupled to connector block256 via awire258 and aplug260.

According to the present invention, theprobe20 further includes an identification element that is characteristic of the particular electrode assembly so that thesame power supply28 can be used for different electrosurgical operations. In one embodiment, for example, the probe (e.g.,20) includes a voltage reduction element or a voltage reduction circuit for reducing the voltage applied between theactive electrodes104 and thereturn electrode112. The voltage reduction element serves to reduce the voltage applied by the power supply so that the voltage between the active electrodes and the return electrodes is low enough to avoid excessive power dissipation into the electrically conducting medium and/or ablation of the soft tissue at the target site. In some embodiments, the voltage reduction element allows thepower supply28 to apply two different voltages simultaneously to two different electrodes (see FIG.15D). In other embodiments, the voltage reduction element primarily allows the electrosurgical probe to be compatible with various electrosurgical generators supplied by ArthroCare Corporation (Sunnyvale, Calif.) that are adapted to apply higher voltages for ablation or vaporization of tissue. For thermal heating or coagulation of tissue, for example, the voltage reduction element will serve to reduce a voltage of about 100 volts rms to 170 volts rms (which is a setting of 1 or 2 on the ArthroCare Model 970 and 980 (i.e., 2000) Generators) to about 45 volts rms to 60 volts rms, which is a suitable voltage for coagulation of tissue without ablation (e.g., molecular dissociation) of the tissue.

Of course, for some procedures, the probe will typically not require a voltage reduction element. Alteratively, the probe may include a voltage increasing element or circuit, if desired. Alternatively or additionally, thecable34 and/or cabledistal end22 that couples thepower supply28 to the probe may be used as a voltage reduction element. The cable has an inherent capacitance that can be used to reduce the power supply voltage if the cable is placed into the electrical circuit between the power supply, the active electrodes and the return electrode. In this embodiment, the cabledistal end22 may be used alone, or in combination with one of the voltage reduction elements discussed above, e.g., a capacitor. Further, it should be noted that the present invention can be used with a power supply that is adapted to apply a voltage within the selected range for treatment of tissue. In this embodiment, a voltage reduction element or circuitry may not be desired.

FIGS. 8A-8C schematically illustrate the distal portion of three different embodiments ofprobe90 according to the present invention. As shown inFIG. 8A,active electrodes104 are anchored in asupport matrix102′ of suitable insulating material (e.g., silicone or a ceramic or glass material, such as alumina, zirconia and the like) which could be formed at the time of manufacture in a flat, hemispherical or other shape according to the requirements of a particular procedure. The preferred support matrix material is alumina, available from Kyocera Industrial Ceramics Corporation, Elkgrove, Ill., because of its high thermal conductivity, good electrically insulative properties, high flexural modulus, resistance to carbon tracking, biocompatiability, and high melting point. Thesupport matrix102′ is adhesively joined to atubular support member78 that extends most or all of the distance betweenmatrix102′ and the proximal end ofprobe90.Tubular member78 preferably comprises an electrically insulating material, such as an epoxy or silicone-based material.

In a preferred construction technique,active electrodes104 extend through pre-formed openings in thesupport matrix102′ so that they protrude abovetissue treatment surface212 by the desired distance. The electrodes are then bonded to thetissue treatment surface212 ofsupport matrix102′, typically by aninorganic sealing material80. Sealingmaterial80 is selected to provide effective electrical insulation, and good adhesion to bothsupport matrix102′ and the platinum or titanium active electrodes. Sealingmaterial80 additionally should have a compatible thermal expansion coefficient and a melting point well below that of platinum or titanium and alumina or zirconia, typically being a glass or glass ceramic.

In the embodiment shown inFIG. 8A, returnelectrode112 comprises an annular member positioned around the exterior ofshaft100 orprobe90.Return electrode112 may fully or partially circumscribetubular support member78 to form anannular gap54 therebetween for flow of electrically conductive liquid50 therethrough, as discussed below.Gap54 preferably has a width in the range of 0.25 mm to 4 mm. Alternatively, probe90 may include a plurality of longitudinal ribs betweensupport member78 andreturn electrode112 to form a plurality of fluid lumens extending along the perimeter ofshaft100. In this embodiment, the plurality of lumens will extend to a plurality of openings.

Return electrode112 is disposed within an electrically insulative jacket118, which is typically formed as one or more electrically insulative sheaths or coatings, such as polytetrafluoroethylene, polyimide, and the like. The provision of the electrically insulative jacket118 overreturn electrode112 prevents direct electrical contact betweenreturn electrode112 and any adjacent body structure. Such direct electrical contact between a body structure (e.g., tendon) and an exposedreturn electrode112 could result in unwanted heating and necrosis of the structure at the point of contact.

As shown inFIG. 8A, returnelectrode112 is not directly connected toactive electrodes104. To complete this current path so thatterminals104 are electrically connected to returnelectrode112, electrically conducting liquid50 (e.g., isotonic saline) is caused to flow along fluid path(s)83.Fluid path83 is formed byannular gap54 betweenreturn electrode112 andtubular support member78. The electrically conductingliquid50 flowing throughfluid path83 provides a pathway for electrical current flow betweenactive electrodes104 and returnelectrode112, as illustrated by thecurrent flux lines60 in FIG.8A. When a voltage difference is applied betweenactive electrodes104 and returnelectrode112, high electric field intensities will be generated at the distal tips ofactive electrodes104 with current flow fromactive electrodes104 through the target tissue to returnelectrode112, the high electric field intensities causing ablation oftissue52 inzone88.

FIG. 8B illustrates another alternative embodiment ofelectrosurgical probe90 which has areturn electrode112 positioned withintubular member78.Return electrode112 is preferably a tubular member defining aninner lumen57 for allowing electrically conducting liquid50 (e.g., isotonic saline) to flow therethrough in electrical contact withreturn electrode112. In this embodiment, a voltage difference is applied betweenactive electrodes104 and returnelectrode112 resulting in electrical current flow through the electrically conductingliquid50 as shown by current flux lines60. As a result of the applied voltage difference and concomitant high electric field intensities at the tips ofactive electrodes104,tissue52 becomes ablated or transected inzone88.

FIG. 8C illustrates another embodiment ofprobe90 that is a combination of the embodiments inFIGS. 8A and 8B. As shown, this probe includes both aninner lumen57 and an outer gap or plurality ofouter lumens54 for flow of electrically conductive fluid. In this embodiment, thereturn electrode112 may be positioned withintubular member78 as inFIG. 8B, outside oftubular member78 as inFIG. 8A, or in both locations.

In some embodiments, theprobe20/90 will also include one or more aspiration electrode(s) coupled to the aspiration lumen for inhibiting clogging during aspiration of tissue fragments from the surgical site. As shown inFIG. 9, one or more of theactive electrodes104 may compriseloop electrodes140 that extend acrossdistal opening209 of the suction lumen withinshaft100. In the representative embodiment, two of theactive electrodes104 compriseloop electrodes140 that cross over thedistal opening209. Of course, it will be recognized that a variety of different configurations are possible, such as a single loop electrode, or multiple loop electrodes having different configurations than shown. In addition, the electrodes may have shapes other than loops, such as the coiled configurations shown inFIGS. 10 and 11. Alternatively, the electrodes may be formed within suction lumen proximal to thedistal opening209, as shown in FIG.13. The main function ofloop electrodes140 is to ablate portions of tissue that are drawn into the suction lumen to prevent clogging of the lumen.

In some embodiments,loop electrodes140 are electrically isolated from the otheractive electrodes104. In other embodiments, theloop electrodes140 andactive electrodes104 may be electrically connected to each other such that both are activated together.Loop electrodes140 may or may not be electrically isolated from each other.Loop electrodes140 will usually extend only about 0.05 mm to 4 mm, preferably about 0.1 mm to 1 mm from the tissue treatment surface ofelectrode support member102.

Referring now toFIGS. 10 and 11, alternative embodiments for aspiration electrodes will now be described. As shown inFIG. 10, the aspiration electrodes may comprise a pair of coiledelectrodes150 that extend acrossdistal opening209 of the suction lumen. The larger surface area of the coiledelectrodes150 usually increases the effectiveness of theelectrodes150 in ablating tissue fragments which may approach or pass throughopening209. InFIG. 11, the aspiration electrode comprises a singlecoiled electrode154 extending across thedistal opening209 of the suction lumen. This single electrode152 may be sufficient to inhibit clogging of the suction lumen. Alternatively, the aspiration electrodes may be positioned within the suction lumen proximal to thedistal opening209. Preferably, these electrodes are close to opening209 so that tissue does not clog theopening209 before it reacheselectrodes154. In this embodiment, a separate return electrode (not shown) may be provided within the suction lumen to confine the electric currents therein.

Referring toFIG. 12, another embodiment of the present invention incorporates awire mesh electrode600 extending across the distal portion ofaspiration lumen162. As shown,mesh electrode600 includes a plurality ofopenings602 to allow fluids and tissue fragments to flow therethrough intoaspiration lumen162. The size of theopenings602 will vary depending on a variety of factors. The mesh electrode may be coupled to the distal or proximal surfaces ofsupport member102.Wire mesh electrode600 comprises a conductive material, such as titanium, tantalum, steel, stainless steel, tungsten, copper, gold or the like. In the representative embodiment,wire mesh electrode600 comprises a different material having a different electric potential than the active electrode(s)104. Preferably,mesh electrode600 comprises steel and active electrode(s)104 comprises tungsten. Applicant has found that a slight variance in the electrochemical potential ofmesh electrode600 and active electrode(s)104 improves the performance of the device. Of course, it will be recognized thatmesh electrode600 may be electrically insulated from active electrode(s)104, as in previous embodiments.

Referring toFIG. 13, another embodiment of the present invention incorporates anaspiration electrode160 within anaspiration lumen162 of the probe. As shown, theelectrode160 is positioned just proximal ofdistal opening209 so that the tissue fragments are ablated as they enterlumen162. In the representative embodiment,aspiration electrode160 comprises a loop electrode that extends across theaspiration lumen162. However, it will be recognized that many other configurations are possible. In this embodiment, thereturn electrode164 is located towards the exterior of the shaft, as in the previously described embodiments. Alternatively, the return electrode(s) may be located within theaspiration lumen162 with theaspiration electrode160. For example, the inner insulating coating163 may be exposed at portions within thelumen162 to provide a conductive path between this exposed portion ofreturn electrode164 and theaspiration electrode160. The latter embodiments has the advantage of confining the electric currents to within the aspiration lumen. In addition, in dry fields in which the conductive fluid is delivered to the target site, it is usually easier to maintain a conductive fluid path between the active and return electrodes in the latter embodiment because the conductive fluid is aspirated through theaspiration lumen162 along with the tissue fragments.

Referring now toFIGS. 14A-14C, an alternative embodiment incorporating ametal screen610 is illustrated. As shown,metal screen610 has a plurality ofperipheral openings612 for receivingactive electrodes104, and a plurality ofinner openings614 for allowing aspiration of fluid and tissue through anopening609 of the aspiration lumen. As shown,screen610 is press fitted overactive electrodes104 and then adhered toshaft100 ofprobe20/90. Similar to the mesh electrode embodiment,metal screen610 may comprise a variety of conductive metals, such as titanium, tantalum, steel, stainless steel, tungsten, copper, gold or the like. In the representative embodiment,metal screen610 is coupled directly to, or integral with, active electrode(s)104. In this embodiment, the active electrode(s)104 and themetal screen610 are electrically coupled to each other.

FIGS. 15A to15D illustrate embodiments of anelectrosurgical probe350 specifically designed for the treatment of herniated or diseased spinal discs. Referring toFIG. 15A,probe350 comprises an electricallyconductive shaft352, ahandle354 coupled to the proximal end ofshaft352 and an electrically insulatingsupport member356 at the distal end ofshaft352. Probe350 further includes a shrink wrapped insulatingsleeve358 overshaft352, and an exposed portion ofshaft352 that functions as thereturn electrode360. In the representative embodiment,probe350 comprises a plurality ofactive electrodes362 extending from the distal end ofsupport member356. As shown,return electrode360 is spaced a further distance fromactive elements362 than in the embodiments described above. In this embodiment, thereturn electrode360 is spaced a distance of about 2.0 mm to 50 mm, preferably about 5 mm to 25 mm fromactive electrodes362. In addition,return electrode360 has a larger exposed surface area than in previous embodiments, having a length in the range of about 2.0 mm to 40 mm, preferably about 5 mm to 20 mm. Accordingly, electric current passing fromactive electrodes362 to returnelectrode360 will follow acurrent flow path370 that is further away fromshaft352 than in the previous embodiments. In some applications, thiscurrent flow path370 results in a deeper current penetration into the surrounding tissue with the same voltage level, and thus increased thermal heating of the tissue. As discussed above, this increased thermal heating may have advantages in some applications of treating disc or other spinal abnormalities. Typically, it is desired to achieve a tissue temperature in the range of about 60° C. to 100° C. to a depth of about 0.2 mm to 5 mm, usually about 1 mm to 2 mm. The voltage required for this thermal damage will partly depend on the electrode configurations, the conductivity of the tissue and the area immediately surrounding the electrodes, the time period in which the voltage is applied and the depth of tissue damage desired. With the electrode configurations described inFIGS. 15A-15D, the voltage level for thermal heating will usually be in the range of about 20 volts rms to 300 volts rms, preferably about 60 volts rms to 200 volts rms. The peak-to-peak voltages for thermal heating with a square wave form having a crest factor of about 2 are typically in the range of about 40 to 600 volts peak-to-peak, preferably about 120 to 400 volts peak-to-peak. The higher the voltage is within this range, the less time required. If the voltage is too high, however, the surface tissue may be vaporized, debulked or ablated, which is undesirable.

In alternative embodiments, the electrosurgical system used in conjunction withprobe350 may include a dispersive return electrode450 (seeFIG. 16) for switching between bipolar and monopolar modes. In this embodiment, the system will switch between an ablation mode, where thedispersive pad450 is deactivated and voltage is applied between active and returnelectrodes362,360 and a subablation or thermal heating mode, where the active electrode(s)362 are deactivated and voltage is applied between thedispersive pad450 and thereturn electrode360. In the subablation mode, a lower voltage is typically applied and thereturn electrode360 functions as the active electrode to provide thermal heating and/or coagulation of tissue surroundingreturn electrode360.

FIG. 15B illustrates yet another embodiment of the present invention. As shown,electrosurgical probe350 comprises anelectrode assembly372 having one or more active electrode(s)362 and a proximally spacedreturn electrode360 as in previous embodiments.Return electrode360 is typically spaced about 0.5 mm to 25 mm, preferably 1.0 mm to 5.0 mm from the active electrode(s)362, and has an exposed length of about 1 mm to 20 mm. In addition,electrode assembly372 includes twoadditional electrodes374,376 spaced axially on either side ofreturn electrode360.Electrodes374,376 are typically spaced about 0.5 mm to 25 mm, preferably about 1 mm to 5 mm fromreturn electrode360. In the representative embodiment, theadditional electrodes374,376 are exposed portions ofshaft352, and thereturn electrode360 is electrically insulated fromshaft352 such that a voltage difference may be applied betweenelectrodes374,376 andelectrode360. In this embodiment,probe350 may be used in at least two different modes, an ablation mode and a subablation or thermal heating mode. In the ablation mode, voltage is applied between active electrode(s)362 and return electrode360 in the presence of electrically conductive fluid, as described above. In the ablation mode,electrodes374,376 are deactivated. In the thermal heating or coagulation mode, active electrode(s)362 are deactivated and a voltage difference is applied betweenelectrodes374,376 andelectrode360 such that a high frequency current370 flows therebetween, as shown in FIG.15B. In the thermal heating mode, a lower voltage is typically applied below the threshold for plasma formation and ablation, but sufficient to cause some thermal damage to the tissue immediately surrounding the electrodes without vaporizing or otherwise debulking this tissue so that the current370 provides thermal heating and/or coagulation oftissue surrounding electrodes360,372,374.

FIG. 15C illustrates another embodiment ofprobe350 incorporating anelectrode assembly372 having one or more active electrode(s)362 and a proximally spacedreturn electrode360 as in previous embodiments.Return electrode360 is typically spaced about 0.5 mm to 25 mm, preferably 1.0 mm to 5.0 mm from the active electrode(s)362, and has an exposed length of about 1 mm to 20 mm. In addition,electrode assembly372 includes a secondactive electrode380 separated fromreturn electrode360 by an electrically insulatingspacer382. In this embodiment, handle354 includes aswitch384 for togglingprobe350 between at least two different modes, an ablation mode and a subablation or thermal heating mode. In the ablation mode, voltage is applied between active electrode(s)362 and return electrode360 in the presence of electrically conductive fluid, as described above. In the ablation mode,electrode380 is deactivated. In the thermal heating or coagulation mode, active electrode(s)362 may be deactivated and a voltage difference is applied betweenelectrode380 andelectrode360 such that a high frequency current370 flows therebetween. Alternatively, active electrode(s)362 may not be deactivated as the higher resistance of the smaller electrodes may automatically send the electric current to electrode380 without having to physically decouple electrode(s)362 from the circuit. In the thermal heating mode, a lower voltage is typically applied below the threshold for plasma formation and ablation, but sufficient to cause some thermal damage to the tissue immediately surrounding the electrodes without vaporizing or otherwise debulking this tissue so that the current370 provides thermal heating and/or coagulation oftissue surrounding electrodes360,380.

Of course, it will be recognized that a variety of other embodiments may be used to accomplish similar functions as the embodiments described above. For example,electrosurgical probe350 may include a plurality of helical bands formed aroundshaft352, with one or more of the helical bands having an electrode coupled to the portion of the band such that one or more electrodes are formed onshaft352 spaced axially from each other.

FIG. 15D illustrates another embodiment of the invention designed for channeling through tissue and creating lesions therein to treat spinal discs and/or snoring and sleep apnea. As shown,probe350 is similar to the probe inFIG. 15C having areturn electrode360 and a third,coagulation electrode380 spaced proximally from thereturn electrode360. In this embodiment,active electrode362 comprises a single electrode wire extending distally from insulatingsupport member356. Of course, theactive electrode362 may have a variety of configurations to increase the current densities on its surfaces, e.g., a conical shape tapering to a distal point, a hollow cylinder, loop electrode and the like. In the representative embodiment,support members356 and382 are constructed of a material, such as ceramic, glass, silicone and the like. Theproximal support member382 may also comprise a more conventional organic material as thissupport member382 will generally not be in the presence of a plasma that would otherwise etch or wear away an organic material.

Theprobe350 inFIG. 15D does not include a switching element. In this embodiment, all three electrodes are activated when the power supply is activated. Thereturn electrode360 has an opposite polarity from the active andcoagulation electrodes362,380 such that current370 flows from the latter electrodes to thereturn electrode360 as shown. In the preferred embodiment, the electrosurgical system includes a voltage reduction element or a voltage reduction circuit for reducing the voltage applied between thecoagulation electrode380 and returnelectrode360. The voltage reduction element allows thepower supply28 to, in effect, apply two different voltages simultaneously to two different electrodes. Thus, for channeling through tissue, the operator may apply a voltage sufficient to provide ablation of the tissue at the tip of the probe (i.e., tissue adjacent to the active electrode362). At the same time, the voltage applied to thecoagulation electrode380 will be insufficient to ablate tissue. For thermal heating or coagulation of tissue, for example, the voltage reduction element will serve to reduce a voltage of about 100 volts rms to 300 volts rms to about 45 volts rms to 90 volts rms, which is a suitable voltage for coagulation of tissue without ablation (e.g., molecular dissociation) of the tissue.

In the representative embodiment, the voltage reduction element comprises a pair of capacitors forming a bridge divider(not shown) coupled to the power supply andcoagulation electrode380. The capacitors usually have a capacitance of about 200 pF to 500 pF (at 500 volts) and preferably about 300 pF to 350 pF (at 500 volts). Of course, the capacitors may be located in other places within the system, such as in, or distributed along the length of, the cable, the generator, the connector, etc. In addition, it will be recognized that other voltage reduction elements, such as diodes, transistors, inductors, resistors, capacitors or combinations thereof, may be used in conjunction with the present invention. For example, theprobe350 may include a coded resistor (not shown) that is constructed to lower the voltage applied between the return andcoagulation electrodes360,380, respectively. In addition, electrical circuits may be employed for this purpose.

Of course, for some procedures, the probe will typically not require a voltage reduction element. Alternatively, the probe may include a voltage increasing element or circuit, if desired. Alternatively or additionally,cable22/34 that couplespower supply28 to theprobe90 may be used as a voltage reduction element. The cable has an inherent capacitance that can be used to reduce the power supply voltage if the cable is placed into the electrical circuit between the power supply, the active electrodes and the return electrode. In this embodiment,cable22/34 may be used alone, or in combination with one of the voltage reduction elements discussed above, e.g., a capacitor. Further, it should be noted that the present invention can be used with a power supply that is adapted to apply two different voltages within the selected range for treatment of tissue. In this embodiment, a voltage reduction element or circuitry may not be desired.

In one specific embodiment, theprobe350 is manufactured by first inserting an electrode wire (active electrode362) through a ceramic tube (insulating member356) such that a distal portion of the wire extends through the distal portion of the tube, and bonding the wire to the tube, typically with an appropriate epoxy. A stainless steel tube (return electrode360) is then placed over the proximal portion of the ceramic tube, and a wire (e.g., nickel wire) is bonded, typically by spot welding, to the inside surface of the stainless steel tube. The stainless steel tube is coupled to the ceramic tube by epoxy, and the device is cured in an oven or other suitable heat source. A second ceramic tube (insulating member382) is then placed inside of the proximal portion of the stainless steel tube, and bonded in a similar manner. Theshaft358 is then bonded to the proximal portion of the second ceramic tube, and an insulating sleeve (e.g., polymide) is wrapped aroundshaft358 such that only a distal portion of the shaft is exposed (i.e., coagulation electrode380). The nickel wire connection will extend through the center ofshaft358 to connectreturn electrode360 to the power supply. Theactive electrode362 may form a distal portion ofshaft358, or it may also have a connector extending throughshaft358 to the power supply.

In use, the physician positionsactive electrode362 adjacent to the tissue surface to be treated (i.e., a spinal disc). The power supply is activated to provide an ablation voltage between active and returnelectrodes362,360, respectively, and a coagulation or thermal heating voltage between coagulation and returnelectrodes380,360, respectively. An electrically conductive fluid can then be provided aroundactive electrode362, and in the junction between the active and returnelectrodes360,362 to provide a current flow path therebetween. This may be accomplished in a variety of manners, as discussed above. Theactive electrode362 is then advanced through the space left by the ablated tissue to form a channel in the disc. During ablation, the electric current between the coagulation and return electrode is typically insufficient to cause any damage to the surface of the tissue as these electrodes pass through the tissue surface into the channel created byactive electrode362. Once the physician has formed the channel to the appropriate depth, he or she will cease advancement of the active electrode, and will either hold the instrument in place for approximately 5 seconds to 30 seconds, or can immediately remove the distal tip of the instrument from the channel (see detailed discussion of this below). In either event, when the active electrode is no longer advancing, it will eventually stop ablating tissue.

Prior to entering the channel formed by theactive electrode362, an open circuit exists between return andcoagulation electrodes360,380. Oncecoagulation electrode380 enters this channel, electric current will flow fromcoagulation electrode380, through the tissue surrounding the channel, to returnelectrode360. This electric current will heat the tissue immediately surrounding the channel to coagulate any severed vessels at the surface of the channel. If the physician desires, the instrument may be held within the channel for a period of time to create a lesion around the channel, as discussed in more detail below.

FIG. 16 illustrates yet another embodiment of an electrosurgical system440 incorporating adispersive return pad450 attached to theelectrosurgical probe400. In this embodiment, the invention functions in the bipolar mode as described above. In addition, the system440 may function in a monopolar mode in which a high frequency voltage difference is applied between the active electrode(s)410, and thedispersive return pad450. In the exemplary embodiment, thepad450 and theprobe400 are coupled together, and are both disposable, single-use items. Thepad450 includes anelectrical connector452 that extends intohandle404 ofprobe400 for direct connection to the power supply. Of course, the invention would also be operable with a standard return pad that connects directly to the power supply. In this embodiment, thepower supply460 will include a switch, e.g., afoot pedal462, for switching between the monopolar and bipolar modes. In the bipolar mode, the return path on the power supply is coupled to return electrode408 onprobe400, as described above. In the monopolar mode, the return path on the power supply is coupled toconnector452 ofpad450, active electrode(s)410 are decoupled from the electrical circuit, and return electrode408 functions as the active electrode. This allows the surgeon to switch between bipolar and monopolar modes during, or prior to, the surgical procedure. In some cases, it may be desirable to operate in the monopolar mode to provide deeper current penetration and, thus, a greater thermal heating of the tissue surrounding the return electrodes. In other cases, such as ablation of tissue, the bipolar modality may be preferable to limit the current penetration to the tissue.

In one configuration, thedispersive return pad450 is adapted for coupling to an external surface of the patient in a region substantially close to the target region. For example, during the treatment of tissue in the head and neck, the dispersive return pad is designed and constructed for placement in or around the patient's shoulder, upper back or upper chest region. This design limits the current path through the patient's body to the head and neck area, which minimizes the damage that may be generated by unwanted current paths in the patient'body, particularly by limiting current flow through the patient's heart. The return pad is also designed to minimize the current densities at the pad, to thereby minimize patient skin burns in the region where the pad is attached.

Referring toFIG. 17, the electrosurgical system according to the present invention may also be configured as acatheter system400. As shown inFIG. 17, acatheter system400 generally comprises anelectrosurgical catheter460 connected to apower supply28 by an interconnectingcable486 for providing high frequency voltage to a target tissue and an irrigant reservoir orsource600 for providing electrically conductive fluid to the target site.Catheter460 generally comprises an elongate,flexible shaft body462 including a tissue removing or ablatingregion464 at the distal end ofbody462. The proximal portion ofcatheter460 includes amulti-lumen fitment614 which provides for interconnections between lumens and electrical leads withincatheter460 and conduits and cables proximal tofitment614. By way of example, a catheterelectrical connector496 is removably connected to adistal cable connector494 which, in turn, is removably connectable togenerator28 throughconnector492. One or more electrically conducting lead wires (not shown) withincatheter460 extend between one or moreactive electrodes463 and acoagulation electrode467 attissue ablating region464 and one or more corresponding electrical terminals (also not shown) incatheter connector496 via active electrode cable branch487. Similarly, areturn electrode466 attissue ablating region464 is coupled to a returnelectrode cable branch489 ofcatheter connector496 by lead wires (not shown). Of course, a single cable branch (not shown) may be used for both active and return electrodes.

Catheter body462 may include reinforcing fibers or braids (not shown) in the walls of at least thedistal ablation region464 ofbody462 to provide responsive torque control for rotation of active electrodes during tissue engagement. This rigid portion of thecatheter body462 preferably extends only about 7 mm to 10 mm while the remainder of thecatheter body462 is flexible to provide good trackability during advancement and positioning of the electrodes adjacent target tissue.

In some embodiments,conductive fluid50 is provided totissue ablation region464 ofcatheter460 via a lumen (not shown inFIG. 17) withincatheter460. Fluid is supplied to the lumen from the source along a conductivefluid supply line602 and aconduit603, which is coupled to the inner catheter lumen atmulti-lumen fitment614. The source of conductive fluid (e.g., isotonic saline) may be an irrigant pump system (not shown) or a gravity-driven supply, such as anirrigant reservoir600 positioned several feet above the level of the patient and tissue ablating region. Acontrol valve604 may be positioned at the interface offluid supply line602 andconduit603 to allow manual control of the flow rate of electricallyconductive fluid50. Alternatively, a metering pump or flow regulator may be used to precisely control the flow rate of the conductive fluid.

System400 can further include an aspiration or vacuum system (not shown) to aspirate liquids and gases from the target site. The aspiration system will usually comprise a source of vacuum coupled tofitment614 by aaspiration connector605.

The present invention is particularly useful in microendoscopic discectomy procedures, e.g., for decompressing a nerve root with a lumbar discectomy. As shown inFIGS. 18-23, apercutaneous penetration270 is made in the patients'back272 so that thesuperior lamina274 can be accessed. Typically, a small needle (not shown) is used initially to localize the disc space level, and a guidewire (not shown) is inserted and advanced under lateral fluoroscopy to the inferior edge of thelamina274. Sequential cannulateddilators276 are inserted over the guide wire and each other to provide a hole from the incision220 to thelamina274. The first dilator may be used to “palpate” thelamina274, assuring proper location of its tip between the spinous process and facet complex just above the inferior edge of thelamina274. As shown inFIG. 21, atubular retractor278 is then passed over the largest dilator down to thelamina274. Thedilators276 are removed, establishing an operating corridor within thetubular retractor278.

As shown inFIG. 19, anendoscope280 is then inserted into thetubular retractor278 and aring clamp282 is used to secure theendoscope280. Typically, the formation of the operating corridor withinretractor278 requires the removal of soft tissue, muscle or other types of tissue that were forced into this corridor as thedilators276 andretractor278 were advanced down to thelamina274. This tissue is usually removed with mechanical instruments, such as pituitary rongeurs, curettes, graspers, cutters, drills, microdebriders, and the like. Unfortunately, these mechanical instruments greatly lengthen and increase the complexity of the procedure. In addition, these instruments sever blood vessels within this tissue, usually causing profuse bleeding that obstructs the surgeon's view of the target site.

According to another aspect of the present invention, an electrosurgical probe orcatheter284 as described above is introduced into the operating corridor within theretractor278 to remove the soft tissue, muscle and other obstructions from this corridor so that the surgeon can easily access and visualization thelamina274. Once the surgeon has introduced theprobe284, electricallyconductive fluid285 can be delivered throughtube233 andopening237 to the tissue (see FIG.4). The fluid flows past thereturn electrode112 to theactive electrodes104 at the distal end of the shaft. The rate of fluid flow is controlled with valve17 (FIG. 1) such that the zone between the tissue andelectrode support102 is constantly immersed in the fluid. Thepower supply28 is then turned on and adjusted such that a high frequency voltage difference is applied betweenactive electrodes104 and returnelectrode112. The electrically conductive fluid provides the conduction path (see current flux lines) betweenactive electrodes104 and thereturn electrode112.

The high frequency voltage is sufficient to convert the electrically conductive fluid (not shown) between the target tissue and active electrode(s)104 into an ionized vapor layer or plasma (not shown). As a result of the applied voltage difference between active electrode(s)104 and the target tissue (i.e., the voltage gradient across the plasma layer), charged particles in the plasma (viz, electrons) are accelerated towards the tissue. At sufficiently high voltage differences, these charged particles gain sufficient energy to cause dissociation of the molecular bonds within tissue structures. This molecular dissociation is accomplished by the volumetric removal (i.e., ablative sublimation) of tissue and the production of low molecular weight gases, such as oxygen, nitrogen, carbon dioxide, hydrogen and methane. The short range of the accelerated charged particles within the tissue confines the molecular dissociation process to the surface layer to minimize damage and necrosis to the underlying tissue.

During the process, the gases will be aspirated throughopening209 andsuction tube211 to a vacuum source. In addition, excess electrically conductive fluid, and other fluids (e.g., blood) will be aspirated from the operating corridor to facilitate the surgeon's view. During ablation of the tissue, the residual heat generated by the current flux lines (typically less than 150° C.), will usually be sufficient to coagulate any severed blood vessels at the site. If not, the surgeon may switch thepower supply28 into the coagulation mode by lowering the voltage to a level below the threshold for fluid vaporization, as discussed above. This simultaneous hemostasis results in less bleeding and facilitates the surgeon's ability to perform the procedure.

Another advantage of the present invention is the ability to precisely ablate soft tissue without causing necrosis or thermal damage to the underlying and surrounding tissues, nerves or bone. In addition, the voltage can be controlled so that the energy directed to the target site is insufficient to ablate thelamina274 so that the surgeon can literally clean the tissue off thelamina274, without ablating or otherwise effecting significant damage to the lamina.

Referring now toFIGS. 20 and 21, once the operating corridor is sufficiently cleared, a laminotomy and medial facetectomy is accomplished either with conventional techniques (e.g., Kerrison punch or a high speed drill) or with theelectrosurgical probe284 as discussed above. After the nerve root is identified, medical retraction can be achieved with aretractor288, or the present invention can be used to precisely ablate the disc. If necessary, epidural veins are cauterized either automatically or with the coagulation mode of the present invention. If an annulotomy is necessary, it can be accomplished with a microknife or the ablation mechanism of the present invention while protecting the nerve root with theretractor288. Theherniated disc290 is then removed with a pituitary rongeur in a standard fashion, or once again through ablation as described above.

In another embodiment, the present invention involves a channeling technique in which small holes or channels are formed within thedisc290, and thermal energy is applied to the tissue surface immediately surrounding these holes or channels to cause thermal damage to the tissue surface, thereby stiffening and debulking the surrounding tissue structure of the disc. Applicant has discovered that such stiffening of the tissue structure in the disc helps to reduce the pressure applied against the spinal nerves by the disc, thereby relieving back and neck pain.

As shown inFIG. 21, theelectrosurgical instrument350 is introduced to the target site at thedisc290 as described above, or in another percutaneous manner (seeFIGS. 23-25 below). Theelectrode assembly351 is positioned adjacent to or against the disc surface, and electrically conductive fluid is delivered to the target site, as described above. Alternatively, the conductive fluid is applied to the target site, or the distal end ofprobe350 is dipped into conductive fluid or gel prior to introducing theprobe350 into the patient. Thepower supply28 is then activated and adjusted such that a high frequency voltage difference is applied to the electrode assembly as described above.

Depending on the procedure, the surgeon may translate or otherwise move the electrodes relative to the target disc tissue to form holes, channels, stripes, divots, craters or the like within the disc. In addition, the surgeon may purposely create some thermal damage within these holes, or channels to form scar tissue that will stiffen and debulk the disc. In one embodiment, the physician axially translates theelectrode assembly351 into the disc tissue as the tissue is volumetrically removed to form one ormore holes702 therein (see also FIG.22). Theholes702 will typically have a diameter of less than 2 mm, preferably less than 1 mm. In another embodiment (not shown), the physician translates the active electrode across the outer surface of the disc to form one or more channels or troughs. Applicant has found that the present invention can quickly and clearly create such holes, divots or channels in tissue with the cold ablation technology described herein. A more complete description of methods for forming holes or channels in tissue can be found in U.S. Pat. No. 5,683,366, the complete disclosure of which is incorporated herein by reference for all purposes.

FIG. 22 is a more detailed viewed of theprobe350 ofFIG. 15D forming ahole702 in adisc290.Hole702 is preferably formed with the methods described in detail above. Namely, a high frequency voltage difference is applied between active and returnelectrodes362,360, respectively, in the presence of an electrically conductive fluid such that an electric current361 passes from theactive electrode362, through the conductive fluid, to thereturn electrode360. As shown inFIG. 22, this will result in shallow or no current penetration into thedisc tissue704. The fluid may be delivered to the target site, applied directly to the target site, or the distal end of the probe may be dipped into the fluid prior to the procedure. The voltage is sufficient to vaporize the fluid aroundactive electrode362 to form a plasma with sufficient energy to effect molecular dissociation of the tissue. The distal end ofprobe350 is then axially advanced through the tissue as the tissue is removed by the plasma in front of theprobe350. Theholes702 will typically have a depth D in the range of about 0.5 cm to 2.5 cm, preferably about 1.2 cm to 1.8 cm, and a diameter d of about 0.5 mm to 5 mm, preferably about 1.0 mm to 3.0 mm. The exact diameter will, of course, depend on the diameter of the electrosurgical probe used for the procedure.

During the formation of eachhole702, the conductive fluid between active and returnelectrodes362,360 will generally minimize current flow into the surrounding tissue, thereby minimizing thermal damage to the tissue. Therefore, severed blood vessels on thesurface705 of thehole702 may not be coagulated as theelectrodes362 advance through the tissue. In addition, in some procedures, it may be desired to thermally damage thesurface705 of theholes702 to stiffen the tissue. For these reasons, it may be desired in some procedures to increase the thermal damage caused to thetissue surrounding hole702. In the embodiment shown inFIG. 15D, it may be necessary to either: (1) withdraw theprobe350 slowly fromhole702 aftercoagulation electrode380 has at least partially advanced past the outer surface of thedisc tissue704 into the hole702 (as shown in FIG.22); or (2) hold theprobe350 within thehole702 for a period of time, e.g., on the order of 1 seconds to 30 seconds. Once the coagulation electrode is in contact with, or adjacent to, tissue, electric current755 flows through thetissue surrounding hole702 and creates thermal damage therein. The coagulation and returnelectrodes380,360 both have relatively large, smooth exposed surfaces to minimize high current densities at their surfaces, which minimizes damage to thesurface705 of hole. Meanwhile, the size and spacing of theseelectrodes360,380 allows for relatively deep current penetration into thetissue704. In the representative embodiment, the thermal necrosis (not shown) will extend about 1.0 mm to 5.0 mm fromsurface705 ofhole702. In this embodiment, the probe may include one or more temperature sensors (not shown) on probe coupled to one or more temperature displays on thepower supply28 such that the physician is aware of the temperature within thehole702 during the procedure.

In other embodiments, the physician switches the electrosurgical system from the ablation mode to the subablation or thermal heating mode after thehole702 has been formed. This is typically accomplished by pressing a switch or foot pedal to reduce the voltage applied to a level below the threshold required for ablation for the particular electrode configuration and the conductive fluid being used in the procedure (as described above). In the subablation mode, the physician will then remove the distal end of theprobe350 from thehole702. As the probe is withdrawn, high frequency current flows from theactive electrodes362 through the surrounding tissue to thereturn electrode360. This current flow heats the tissue and coagulates severed blood vessels atsurface705.

In another embodiment, the electrosurgical probe of the present invention can be used to ablate and/or contract soft tissue within thedisc290 to allow theannulus fibrosus292 to repair itself to prevent reoccurrence of this procedure. For tissue contraction, a sufficient voltage difference is applied between theactive electrodes104 and thereturn electrode112 to elevate the tissue temperature from normal body temperature (e.g., 37° C.) to temperatures in the range of 45° C. to 90° C., preferably in the range from 60° C. to 70° C. This temperature elevation causes contraction of the collagen connective fibers within the disc tissue so that the nucleus pulposus withdraws into theannulus fibrosus292.

In one method of tissue contraction according to the present invention, an electrically conductive fluid is delivered to the target site as described above, and heated to a sufficient temperature to induce contraction or shrinkage of the collagen fibers in the target tissue. The electrically conductive fluid is heated to a temperature sufficient to substantially irreversibly contract the collagen fibers, which generally requires a tissue temperature in the range of about 45° C. to 90° C., usually about 60° C. to 70° C. The fluid is heated by applying high frequency electrical energy to the active electrode(s) in contact with the electrically conductive fluid. The current emanating from the active electrode(s)104 heats the fluid and generates a jet or plume of heated fluid, which is directed towards the target tissue. The heated fluid elevates the temperature of the collagen sufficiently to cause hydrothermal shrinkage of the collagen fibers. Thereturn electrode112 draws the electric current away from the tissue site to limit the depth of penetration of the current into the tissue, thereby inhibiting molecular dissociation and breakdown of the collagen tissue and minimizing or completely avoiding damage to surrounding and underlying tissue structures beyond the target tissue site. In an exemplary embodiment, the active electrode(s)104 are held away from the tissue a sufficient distance such that the RF current does not pass into the tissue at all, but rather passes through the electrically conductive fluid back to the return electrode. In this embodiment, the primary mechanism for imparting energy to the tissue is the heated fluid, rather than the electric current.

In an alternative embodiment, the active electrode(s)104 are brought into contact with, or close proximity to, the target tissue so that the electric current passes directly into the tissue to a selected depth. In this embodiment, the return electrode draws the electric current away from the tissue site to limit its depth of penetration into the tissue. Applicant has discovered that the depth of current penetration also can be varied with the electrosurgical system of the present invention by changing the frequency of the voltage applied to the active electrode and the return electrode. This is because the electrical impedance of tissue is known to decrease with increasing frequency due to the electrical properties of cell membranes which surround electrically conductive cellular fluid. At lower frequencies (e.g., less than 350 kHz), the higher tissue impedance, the presence of the return electrode and the active electrode configuration of the present invention (discussed in detail below) cause the current flux lines to penetrate less deeply resulting in a smaller depth of tissue heating. In an exemplary embodiment, an operating frequency of about 100 kHz to 200 kHz is applied to the active electrode(s) to obtain shallow depths of collagen shrinkage (e.g., usually less than 1.5 mm and preferably less than 0.5 mm).

In another aspect of the invention, the size (e.g., diameter or principle dimension) of the active electrodes employed for treating the tissue are selected according to the intended depth of tissue treatment. As described previously in co-pending patent application PCT International Application, U.S. National Phase Ser. No. PCT/US94/05168, the depth of current penetration into tissue increases with increasing dimensions of an individual active electrode (assuming other factors remain constant, such as the frequency of the electric current, the return electrode configuration, etc.). The depth of current penetration (which refers to the depth at which the current density is sufficient to effect a change in the tissue, such as collagen shrinkage, irreversible necrosis, etc.) is on the order of the active electrode diameter for the bipolar configuration of the present invention and operating at a frequency of about 100 kHz to about 200 kHz. Accordingly, for application requiring a smaller depth of current penetration, one or more active electrodes of smaller dimensions would be selected. Conversely, for application requiring a greater depth of current penetration, one or more active electrodes of larger dimensions would be selected.

FIGS. 23-25 illustrate another system and method for treating swollen or herniated spinal discs according to the present invention. In this procedure, an electrosurgical probe800 comprises a long, thin needle-like shaft802 (e.g., on the order of about 1 mm in diameter or less) that can be percutaneously introduced posteriorly through the patient's back directly into the spine. The shaft802 may or may not be flexible, depending on the method of access chosen by the physician. The probe shaft802 will include one or more active electrode(s)804 for applying electrical energy to tissues within the spine. The probe800 may include one or more return electrode(s)806, or the return electrode may be positioned on the patient's back, as a dispersive pad (not shown). As discussed below, however, a bipolar design is preferable.

As shown inFIG. 23, the distal portion of shaft802 is introduced anteriorly through a small percutaneous penetration into theannulus fibrosus292 of the target spinal disc. To facilitate this process, the distal end of shaft802 may taper down to a sharper point (e.g., a needle), which can then be retracted to expose active electrode(s)804. Alternatively, the electrodes may be formed around the surface of the tapered distal portion of shaft (not shown). In either embodiment, the distal end of shaft is delivered through theannulus292 to thetarget nucleus pulposus294, which may be herniated, extruded, non-extruded, or simply swollen. As shown inFIG. 24, high frequency voltage is applied between active electrode(s)804 and return electrode(s)806 to heat the surrounding collagen to suitable temperatures for contraction (i.e., typically about 55° C. to about 70° C.). As discussed above, this procedure may be accomplished with a monopolar configuration as well. However, applicant has found that the bipolar configuration shown inFIGS. 23-25 provides enhanced control of the high frequency current, which reduces the risk of spinal nerve damage.

As shown inFIG. 24 and 25, once thenucleus pulposus294 has been sufficiently contracted to retract from impingement on thenerve720, the probe800 is removed from the target site. In the representative embodiment, the high frequency voltage is applied between active and return electrode(s)804,806 as the probe is withdrawn through theannulus292. This voltage is sufficient to cause contraction of the collagen fibers within theannulas292, which allows theannulus292 to contract around the hole formed by probe800, thereby improving the healing of this hole. Thus, the probe800 seals its own passage as it is withdrawn from the disc.

FIG. 26A is a side view of anelectrosurgical probe900, according to one embodiment of the invention.Probe900 includes ashaft902 having adistal end portion902a and aproximal end portion902b. Anactive electrode910 is disposed ondistal end portion902a. Although only one active electrode is shown inFIG. 26A, embodiments including a plurality of active electrodes are also within the scope of the invention. Probe900 further includes ahandle904 which houses aconnection block906 for coupling electrodes, e.g.active electrode910, thereto.Connection block906 includes a plurality ofpins908 adapted forcoupling probe900 to a power supply unit, e.g. power supply28 (FIG.1).

FIG. 26B is a side view of the distal end portion of the electrosurgical probe ofFIG. 26A, showing details of shaftdistal end portion902a.Distal end portion902a includes an insulating collar orspacer916 proximal toactive electrode910, and areturn electrode918 proximal tocollar916. A first insulating sleeve (FIG. 28B) may be located beneathreturn electrode918. A second insulating jacket orsleeve920 may extend proximally fromreturn electrode918. Second insulatingsleeve920 serves as an electrical insulator to inhibit current flow into the adjacent tissue. In a currently preferred embodiment, probe900 further includes ashield922 extending proximally from second insulatingsleeve920.Shield922 may be formed from a conductive metal such as stainless steel, and the like.Shield922 functions to decrease the amount of leakage current passing fromprobe900 to a patient or a user (e.g., surgeon). In particular, shield922 decreases the amount of capacitive coupling betweenreturn electrode918 and an introducer needle928 (FIG.31A). Typically shield922 is coupled to an outer floating conductive layer or cable shield (not shown) of a cable,e.g. cables22,34 (FIG.1), connectingprobe900 topower supply28. In this way, the capacitor balance ofshaft902 is disturbed. In one embodiment, shield922 may be coated with a durable, hard compound such as titanium nitride. Such a coating has the advantage of providing reduced friction betweenshield922 and introducerinner wall932 asshaft902 is axially translated within introducer needle928 (e.g.,FIGS. 31A,31B).

FIG. 27A is a side view of anelectrosurgical probe900 showing afirst curve924 and asecond curve926 located atdistal end portion902a, whereinsecond curve926 is proximal tofirst curve924.First curve924 andsecond curve926 may be separated by a linear (i.e. straight, or non-curved), or substantially linear,inter-curve portion925 ofshaft902.

FIG. 27B is a side view of shaftdistal end portion902a within a representative introducer device orneedle928 having an inner diameter D. Shaftdistal end portion902a includesfirst curve924 andsecond curve926 separated byinter-curve portion925. In one embodiment, shaftdistal end portion902a includes a linear or substantially linear proximal portion901 extending frompromixal end portion902b tosecond curve926, a linear or substantially linearinter-curve portion925 between first andsecond curves924,926, and a linear or substantially lineardistal portion909 betweenfirst curve924 and the distal tip of shaft902 (the distal tip is represented inFIG. 27B as an electrode head911). When shaftdistal end portion902a is located withinintroducer needle928,first curve924 subtends a first angle ∀ to the inner surface ofneedle928, andsecond curve926 subtends a second angle ∃ toinner surface932 ofneedle928. (In the situation shown inFIG. 27B, needleinner surface932 is essentially parallel to the longitudinal axis of shaftproximal end portion902b (FIG.27A).) In one embodiment, shaftdistal end portion902a is designed such that the shaft distal tip occupies a substantially central transverse location within the lumen ofintroducer needle928 when shaftdistal end portion902a is translated axially with respect tointroducer needle928. Thus, as shaftdistal end portion902a is advanced through the distal opening of needle928 (FIGS. 30B,31B), and then retracted back into the distal opening, the shaft distal tip will always occupy a transverse location towards the center of introducer needle928 (even though the tip may be curved or biased away from the longitudinal axis ofshaft902 andneedle928 upon its advancement past the distal opening of introducer needle928). In one embodiment, shaftdistal end portion902a is flexible and has a configuration which requires shaftdistal end portion902a be distorted in the region of at leastsecond curve926 by application of a lateral force imposed byinner wall932 ofintroducer needle928 as shaftdistal end portion902a is introduced or retracted intoneedle928. In one embodiment,first curve924 andsecond curve926 are in the same plane relative to the longitudinal axis ofshaft902, and first andsecond curves924,926 are in opposite directions.

The “S-curve” configuration ofshaft902 shown inFIGS. 27A-C allows the distal end or tip of a device to be advanced or retracted through the needledistal end928a and within the lumen ofneedle928 without the distal end or tip contacting sensitive or delicate component to be located at the distal tip of a device, wherein the distal end or tip is advanced or retracted through a lumen of an introducer instrument comprising a relatively hard material (e.g., an introducer needle comprising stainless steel). This design also allows a component located at a distal end or tip of a device to be constructed from a relatively soft material, and for the component located at the distal end or tip to be passed through an introducer instrument comprising a hard material without risking damage to the component comprising a relatively soft material.

The “S-curve” design of shaftdistal end portion902a allows the distal tip (e.g., electrode head911) to be advanced and retracted through the distal opening ofneedle928 while avoiding contact between the distal tip and the edges of the distal opening ofneedle928. (If, for example, shaftdistal end portion902a included only a single curve the distal tip would ordinarily come into contact with needledistal end928a asshaft902 is retracted into the lumen ofneedle928.) In preferred embodiments, the length L2 ofdistal portion909 and the angle ∀ betweendistal portion909 and needleinner surface932928, when shaftdistal end portion902a is compressed withinneedle928, are selected such that the distal tip is substantially in the center of the lumen ofneedle928, as shown in FIG.27B. Thus, as the length L2 increases, the angle ∀ will decrease, and vice versa. The exact values of length L2 and angle ∀ will depend on the inner diameter, D ofneedle928, the inner diameter, d of shaftdistal end portion902a, and the size of the shaft distal tip.

The presence of first and second curves,924,926 provides a pre-defined bias inshaft902. In addition, in one embodiment shaftdistal end portion902a is designed such that at least one of first andsecond curves924,926 are compressed to some extent as shaftdistal end portion902a is retracted into the lumen ofneedle928. Accordingly, the angle of at least one ofcurves924,926 may be changed whendistal end portion902a is advanced out through the distal opening ofintroducer needle928, as compared with the corresponding angle when shaft distal end portion is completely retracted withinintroducer needle928. For example,FIG. 27C showsshaft902 ofFIG. 27B free fromintroducer needle928, wherein first andsecond curves924,926 are allowed to adopt their natural or uncompressed angles ∀′ and ∃′, respectively, wherein ∃′ is typically equal to or greater than ∃. Angle ∀′ may be greater than, equal to, or less than angle ∀. Angle ∃′ is subtended byinter-curve portion925 and proximal portion901. When shaftdistal end portion902a is unrestrained byintroducer needle928, proximal portion901 approximates the longitudinal axis ofshaft902. Angle ∀′ is subtended between lineardistal portion909 and a line drawn parallel to proximal portion901.Electrode head911 is omitted fromFIG. 27C for the sake of clarity.

The principle described above with reference toshaft902 andintroducer needle928 may equally apply to a range of other medical devices. That is to say, the “S-curve” configuration of the invention may be included as a feature of any medical system or apparatus in which a medical instrument may be axially translated or passed within an introducer device. In particular, the principle of the “S-curve” configuration of the invention may be applied to any apparatus wherein it is desired that the distal end of the medical instrument does not contact or impinge upon the introducer device as the medical instrument is advanced from or retracted into the introducer device. The introducer device may be any apparatus through which a medical instrument is passed. Such medical systems may include, for example, a catheter, a cannula, an endoscope, and the like.

Whenshaft902 is advanced distally through the needle lumen to a point wheresecond curve926 is located distal to needledistal end928a, the shaft distal tip is deflected from the longitudinal axis ofneedle928. The amount of this deflection is determined by the relative size of angles ∃′ and ∀′, and the relative lengths of L1 and L2. The amount of this deflection will in turn determine the size of a channel or lesion (depending on the application) formed in a tissue treated byelectrode head911 whenshaft902 is rotated circumferentially with respect to the longitudinal axis ofprobe900.

As a result of the pre-defined bias inshaft902, shaftdistal end portion902a will contact a larger volume of tissue than a linear shaft having the same dimensions. In addition, in one embodiment the pre-defined bias ofshaft902 allows the physician to guide or steer the distal tip ofshaft902 by a combination of axial movement of needledistal end928a and the inherent curvature at shaftdistal end portion902a ofprobe900.

Shaft902 preferably has a length in the range of from about 4 to 30 cm. In one aspect of the invention,probe900 is manufactured in a range of sizes having different lengths and/or diameters ofshaft902. A shaft of appropriate size can then be selected by the surgeon according to the body structure or tissue to be treated and the age or size of the patient. In this way, patients varying in size from small children to large adults can be accommodated. Similarly, for a patient of a given size, a shaft of appropriate size can be selected by the surgeon depending on the organ or tissue to be treated, for example, whether an intervertebral disc to be treated is in the lumbar spine or the cervical spine. For example, a shaft suitable for treatment of a disc of the cervical spine may be substantially smaller than a shaft for treatment of a lumbar disc. For treatment of a lumbar disc in an adult,shaft902 is preferably in the range of from about 15 to 25 cm. For treatment of a cervical disc,shaft902 is preferably in the range of from about 4 to about 15 cm.

The diameter ofshaft902 is preferably in the range of from about 0.5 to about 2.5 mm, and more preferably from about 1 to 1.5 mm.First curve924 is characterized by a length L1, whilesecond curve926 is characterized by a length L2 (FIG.27B).Inter-curve portion925 is characterized by a length L3, whileshaft902 extends distally from first curve924 a length L4. In one embodiment, L2 is greater than L1. Length L1 may be in the range of from about 0.5 to about 5 mm, while L2 may be in the range of from about 1 to about 10 mm. Preferably, L3 and L4 are each in the range of from about 1 to 6 mm.

FIG. 28A is a side view of shaftdistal end portion902a ofelectrosurgical probe900 showing ahead911 of active electrode910 (the latter not shown in FIG.28A), according to one embodiment of the invention. In this embodiment,electrode head911 includes anapical spike911a and an equatorial cusp911b.Electrode head911 exhibits a number of advantages as compared with, for example, an electrosurgical probe having a blunt, globular, or substantially spherical active electrode. In particular,electrode head911 provides a high current density atapical spike911a and cusp911b. In turn, high current density in the vicinity of an active electrode is advantageous in the generation of a plasma; and, as is described fully hereinabove, generation of a plasma in the vicinity of an active electrode is fundamental to ablation of tissue with minimal collateral thermal damage according to certain embodiments of the instant invention.Electrode head911 provides an additional advantage, in that the sharp edges of cusp911b, and more particularly ofapical spike911a, facilitate movement and guiding ofhead911 into tissue during surgical procedures, as described fully hereinbelow. In contrast, an electrosurgical probe having a blunt or rounded apical electrode is more likely to follow a path of least resistance, such as a channel which was previously ablated within nucleus pulposus tissue. Although certain embodiments of the invention depicthead911 as having a single apical spike, other shapes for the apical portion ofactive electrode910 are also within the scope of the invention.

FIG. 28B is a longitudinal cross-sectional view ofdistal end portion902a ofshaft902.Apical electrode head911 is in communication with afilament912.Filament912 typically comprises an electrically conductive wire encased within a firstinsulating sleeve914. First insulatingsleeve914 comprises an insulator, such as various synthetic polymeric materials. An exemplary material from which first insulatingsleeve914 may be constructed is a polyimide. First insulatingsleeve914 may extend the entire length ofshaft902 proximal tohead911. An insulating collar orspacer916 is disposed on the distal end of firstinsulating sleeve914, adjacent toelectrode head911.Collar916 preferably comprises a material such as a glass, a ceramic, or silicone. The exposed portion of first insulating sleeve914 (i.e., the portion proximal to collar916) is encased within acylindrical return electrode918.Return electrode918 may extend proximally the entire length ofshaft902.Return electrode918 may comprise an electrically conductive material such as stainless steel, tungsten, platinum or its alloys, titanium or its alloys, molybdenum or its alloys, nickel or its alloys, and the like. A proximal portion ofreturn electrode918 is encased within a secondinsulating sleeve920, so as to provide an exposed band ofreturn electrode918 located distal tosecond sleeve920 and proximal tocollar916.Second sleeve920 provides an insulated portion ofshaft920 which facilitates handling ofprobe900 by the surgeon during a surgical procedure. A proximal portion ofsecond sleeve920 is encased within an electricallyconductive shield922.Second sleeve920 and shield922 may also extend proximally for the entire length ofshaft902.

FIG. 29 is a side view of shaftdistal end portion902a ofelectrosurgical probe900, indicating the position of first andsecond curves924,926, respectively.Probe900 includeshead911,collar916,return electrode918, second insulatingsleeve920, and shield922, generally as described with reference toFIGS. 28A,28B. In the embodiment ofFIG. 29,first curve924 is located withinreturn electrode918, whilesecond curve926 is located withinshield922. However, according to various embodiments of the invention,shaft902 may be provided in which one or more curves are present at alternative or additional locations or components ofshaft902, other than the locations of first andsecond curves924,926, respectively, shown in FIG.29.

FIG. 30A showsdistal end portion902a ofshaft902 extended distally from anintroducer needle928, according to one embodiment of the invention.Introducer needle928 may be used to conveniently introduceshaft902 into tissue, such as the nucleus pulposus of an intervertebral disc. In this embodiment, due to the curvature of shaftdistal end902a, whenshaft902 is extended distally beyondintroducer needle928,head911 is displaced laterally from the longitudinal axis ofintroducer needle928. However, as shown inFIG. 30B, asshaft902 is retracted intointroducer needle928,head911 assumes a substantially central transverse location with lumen930 (see alsoFIG. 31B) ofintroducer928. Such re-alignment ofhead911 with the longitudinal axis ofintroducer928 is achieved by specific design of the curvature of shaftdistal end902a, as accomplished by the instant inventors. In this manner, contact of various components of shaftdistal end902a (e.g.,electrode head911,collar916, return electrode918) is prevented, thereby not only facilitating extension and retraction ofshaft902 withinintroducer928, but also avoiding a potential source of damage to sensitive components ofshaft902.

FIG. 31A shows a side view ofshaft902 in relation to aninner wall932 ofintroducer needle928 upon extension or retraction ofelectrode head911 from, or withinintroducer needle928.Shaft902 is located withinintroducer928 withhead911 adjacent to introducerdistal end928a (FIG.31B). Under these circumstances, curvature ofshaft902 may cause shaftdistal end902a to be forced into contact with introducerinner wall932, e.g., at a location ofsecond curve926. Nevertheless, due to the overall curvature ofshaft902, and in particular the nature and position of first curve924 (FIGS.27A-B),head911 does not contact introducerdistal end928a.

FIG. 31B shows an end view ofelectrode head911 in relation tointroducer needle928 at a point during extension or retraction ofshaft902, whereinhead911 is adjacent to introducerdistal end928a (FIGS. 30B,31B). In this situation, head91 is substantially centrally positioned withinlumen930 ofintroducer928. Therefore, contact betweenhead911 andintroducer928 is avoided, allowing shaftdistal end902a to be extended and retracted repeatedly without sustaining any damage toshaft902.

FIG. 32A shows shaftproximal end portion902b ofelectrosurgical probe900, whereinshaft902 includes a plurality of depth markings903 (shown as903a-f in FIG.32A). In other embodiments, other numbers and arrangements of depth markings903 may be included onshaft902. For example, in certain embodiments, depth markings may be present along the entire length ofshield922, or a single depth marking903 may be present at shaftproximal end portion902b. Depth markings serve to indicate to the surgeon the depth of penetration ofshaft902 into a patient's tissue, organ, or body, during a surgical procedure. Depth markings903 may be formed directly in or onshield922, and may comprise the same material asshield922. Alternatively, depth markings903 may be formed from a material other than that ofshield922. For example, depth markings may be formed from materials which have a different color and/or a different level of radiopacity, as compared with material ofshield922. For example, depth markings may comprise a metal, such as tungsten, gold, or platinum oxide (black), having a level of radiopacity different from that ofshield922. Such depth markings may be visualized by the surgeon during a procedure performed under fluoroscopy. In one embodiment, the length of the introducer needle and theshaft902 are selected to limit the range of the shaft beyond the distal tip of the introducer needle.

FIG. 32B shows aprobe900, whereinshaft902 includes amechanical stop905. Preferably,mechanical stop905 is located at shaftproximal end portion902b.Mechanical stop905 limits the distance to which shaftdistal end902a can be advanced throughintroducer928 by making mechanical contact with a proximal end928b ofintroducer928.Mechanical stop905 may be a rigid material or structure affixed to, or integral with,shaft902.Mechanical stop905 also serves to monitor the depth or distance of advancement of shaftdistal end902a throughintroducer928, and the degree of penetration ofdistal end902a into a patient's tissue, organ, or body. In one embodiment,mechanical stop905 is movable onshaft902, and stop905 includes astop adjustment unit907 for adjusting the position ofstop905 and for lockingstop905 at a selected location onshaft902.

FIG. 33 illustrates stages in manufacture of anactive electrode910 of ashaft902, according to one embodiment of the present invention. Stage33-I shows an elongated piece of electricallyconductive material912′, e.g., a metal wire, as is well known in the art.Material912′ includes afirst end912′a and asecond end912′b. Stage33-II shows the formation of aglobular structure911′ fromfirst end912′a, whereinglobular structure911′ is attached tofilament912.Globular structure911′ may be conveniently formed by applying heat tofirst end912′a. Techniques for applying heat to the end of a metal wire are well known in the art. Stage33-III shows the formation of anelectrode head911 fromglobular structure911′, whereinactive electrode910 compriseshead911 andfilament912 attached tohead911. In this particular embodiment,head911 includes anapical spike911a and a substantially equatorial cusp911b.

FIG. 34 schematically represents a series of steps involved in a method of making a shaft according to one embodiment of the present invention, whereinstep1000 involves providing an active electrode having a filament, the active electrode including an electrode head attached to the filament. An exemplary active electrode to be provided instep1000 is an electrode of the type described with reference to FIG.33. At this stage (step1000), the filament may be trimmed to an appropriate length for subsequent coupling to a connection block (FIG.26A).

Step1002 involves covering or encasing the filament with a first insulating sleeve of an electrically insulating material such as a synthetic polymer or plastic, e.g., a polyimide. Preferably, the first insulating sleeve extends the entire length of the shaft.Step1004 involves positioning a collar of an electrically insulating material on the distal end of the first insulating sleeve, wherein the collar is located adjacent to the electrode head. The collar is preferably a material such as a glass, a ceramic, or silicone.Step1006 involves placing a cylindrical return electrode over the first insulating sleeve. Preferably, the return electrode is positioned such that its distal end is contiguous with the proximal end of the collar, and the return electrode preferably extends proximally for the entire length of the shaft. The return electrode may be constructed from stainless steel of other non-corrosive, electrically conductive metal.

According to one embodiment, a metal cylindrical return electrode is prebent to include a curve within its distal region (i.e. the return electrode component is bent prior to assembly onto the shaft). As a result, the shaft assumes a first curve upon placing the return electrode over the first insulating sleeve, i.e. the first curve in the shaft results from the bend in the return electrode.Step1008 involves covering a portion of the return electrode with a second insulating layer or sleeve such that a band of the return electrode is exposed distal to the distal end of the second insulating sleeve. In one embodiment, the second insulating sleeve comprises a heat-shrink plastic material which is heated prior to positioning the second insulating sleeve over the return electrode. According to one embodiment, the second insulating sleeve is initially placed over the entire length of the shaft, and thereafter the distal end of the second insulating sleeve is cut back to expose an appropriate length of the return electrode.Step1010 involves encasing a proximal portion of the second insulating sleeve within a shield of electrically conductive material, such as a cylinder of stainless steel or other metal, as previously described herein.

FIG. 35 schematically represents a series of steps involved in a method of making an electrosurgical probe of the present invention, whereinstep1100 involves providing a shaft having at least one active electrode and at least one return electrode. An exemplary shaft to be provided instep1100 is that prepared according to the method described hereinabove with reference toFIG. 34, i.e., the shaft includes a first curve.Step1102 involves bending the shaft to form a second curve. Preferably, the second curve is located at the distal end portion of the shaft, but proximal to the first curve. In one embodiment, the second curve is greater than the first curve. (Features of both the first curve and second curve have been described hereinabove, e.g., a handle for the probe. The handle includes a connection block for electrically coupling the electrodes thereto.Step1106 involves coupling the active and return electrodes of the shaft to the connection block. The connection block allows for convenient coupling of the electrosurgical probe to a power supply (e.g.,power supply28, FIG.1). Thereafter,step1108 involves affixing the shaft to the handle.

FIG. 36A schematically represents a normalintervertebral disc290 in relation to thespinal cord720, the intervertebral disc having anouter annulus fibrosus292 enclosing aninner nucleus pulposus294. The nucleus pulposus is a relatively soft tissue comprising proteins and having a relatively high water content, as compared with the harder, more fibrous annulus fibrosus.FIGS. 36B-D each schematically represent an intervertebral disc having a disorder which can lead to discogenic pain, for example due to compression of a nerve root by a distorted annulus fibrosus. Thus,FIG. 36B schematically represents an intervertebral disc exhibiting a protrusion of the nucleus pulposus and a concomitant distortion of the annulus fibrosus. The condition depicted inFIG. 36B clearly represents a contained herniation, which can result in severe and often debilitating pain.FIG. 36C schematically represents an intervertebral disc exhibiting a plurality of fissures within the annulus fibrosus, again with concomitant distortion of the annulus fibrosus. Excessive pressure within the nucleus pulposus tends to intensify disc disorders associated with the presence of such fissures.FIG. 36D schematically represents an intervertebral disc exhibiting fragmentation of the nucleus pulposus and a concomitant distortion of the annulus fibrosus. In this situation, over time,errant fragment294′ of the nucleus pulposus tends to dehydrate and to diminish in size, often leading to a decrease in discogenic pain over an extended period of time (e.g., several months). For the sake of clarity, eachFIG. 36B,36C,36D shows a single disorder. However, in practice more than one of the depicted disorders may occur in the same disc.

Many patients suffer from discogenic pain resulting, for example, from conditions of the type depicted inFIGS. 36B-D. However, only a small percentage of such patients undergo laminotomy or discectomy. Presently, there is a need for interventional treatment for the large group of patients who ultimately do not undergo major spinal surgery, but who sustain significantly disability due to various disorders or abnormalities of an intervertebral disc. A common disorder of intervertebral discs is a contained herniation in which the nucleus pulposus does not breach the annulus fibrosus, but a protrusion of the disc causes compression of the exiting nerve root, leading to radicular pain. Typical symptoms are leg pain compatible with sciatica. Such radicular pain may be considered as a particular form of discogenic pain. Most commonly, contained herniations leading to radicular pain are associated with the lumbar spine, and in particular with intervertebral discs at either L4-5 or L5-S1. Various disc abnormalities are also encountered in the cervical spine. Methods and apparatus of the invention are applicable to all segments of the spine, including the cervical spine and the lumber spine.

FIG. 37 schematically representsshaft902 ofprobe900 inserted within a nucleus pulposus of a disc having at least one fissure in the annulus.Shaft902 may be conveniently inserted within the nucleus pulposus viaintroducer needle928 in a minimally invasive percutaneous procedure. In a preferred embodiment, a disc in the lumbar spine may be accessed via a posterior lateral approach, although other approaches are possible and are within the scope of the invention. The preferred length and diameter ofshaft902 andintroducer needle928 to be used in a procedure will depend on a number of factors, including the region of the spine (e.g., lumbar, cervical) or other body region to be treated, and the size of the patient. Preferred ranges forshaft902 are given elsewhere herein. In one embodiment for treatment of a lumbar disc,introducer needle928 preferably has a diameter in the range of from about 50% to 150% the inside diameter of a 17 Gauge needle. In an embodiment for treatment of a cervical disc,introducer needle928 preferably has a diameter in the range of from about 50% to 150% the inner diameter of a 20 Gauge needle.

Shaft902 includes anactive electrode910, as described hereinabove.Shaft902 features curvature atdistal end902a/902′a, for example, as described with reference toFIGS. 27A-B. By rotatingshaft902 through approximately 180°, shaftdistal end902a can be moved to a position indicated by the dashed lines and labeled as902′a. Thereafter, rotation ofshaft902 through an additional 180° defines a substantially cylindrical three-dimensional space with a proximal conical area represented as a hatched area (shown between902a and902′a). The bidirectional arrow distal toactive electrode910 indicates translation ofshaft902 substantially along the longitudinal axis ofshaft902. By a combination of axial and rotational movement ofshaft902, a much larger volume of the nucleus pulposus can be contacted byelectrode910, as compared with a corresponding probe having a linear (non-curved) shaft. Furthermore, the curved nature ofshaft902 allows the surgeon to change the direction of advancement ofshaft902 by appropriate rotation thereof, and to guide shaftdistal end902a to a particular target site within the nucleus pulposus.

It is to be understood that according to certain embodiments of the invention, the curvature ofshaft902 is the same, or substantially the same, both prior to it being used in a surgical procedure and while it is performing ablation during a procedure, e.g., within an intervertebral disc. (One apparent exception to this statement, relates to the stage in a procedure whereinshaft902 may be transiently “molded” into a somewhat more linear configuration by the constraints of introducerinner wall932 during housing, or passing, orshaft902 withinintroducer928.) In contrast, certain prior art devices, and embodiments of the invention to be described hereinbelow (e.g., with reference toFIG. 43A,43B), may be linear or lacking a naturally defined configuration prior to use, and then be steered into a selected configuration during a surgical procedure.

While shaftdistal end902a is at or adjacent to a target site within the nucleus pulposus,probe900 may be used to ablate tissue by application of a first high frequency voltage betweenactive electrode910 and return electrode918 (e.g., FIG.26B), wherein the volume of the nucleus pulposus is decreased, the pressure exerted by the nucleus pulposus on the annulus fibrosus is decreased, and at least one nerve or nerve root is decompressed. Accordingly, discogenic pain experienced by the patient may be alleviated. Preferably, application of the first high frequency voltage results in formation of a plasma in the vicinity ofactive electrode910, and the plasma causes ablation by breaking down high molecular weight disc tissue components (e.g., proteins) into low molecular weight gaseous materials. Such low molecular weight gaseous materials may be at least partially vented or exhausted from the disc, e.g., by piston action, upon removal of theshaft902 andintroducer928 from the disc and the clearance between theintroducer928 and theshaft902. In addition, by-products of tissue ablation may be removed by an aspiration device (not shown in FIG.37), as is well known in the art. In this manner, the volume and/or mass of the nucleus pulposus may be decreased.

In order to initiate and/or maintain a plasma in the vicinity ofactive electrode910, a quantity of an electrically conductive fluid may be applied toshaft902 and/or the tissue to ablated. The electrically conductive fluid may be applied toshaft902 and/or to the tissue to be ablated, either before or during application of the first high frequency voltage. Examples of electrically conductive fluids are saline (e.g., isotonic saline), and an electrically conductive gel. An electrically conductive fluid may be applied to the tissue to be ablated before or during ablation. A fluid delivery unit or device may be a component of the electrosurgical probe itself, or may comprise a separate device, e.g., ancillary device940 (FIG.41). Alternatively, many body fluids and/or tissues (e.g., the nucleus pulposus, blood) at the site to be ablated are electrically conductive and can participate in initiation or maintenance of a plasma in the vicinity of the active electrode.

In one embodiment, after ablation of nucleus pulposus tissue by the application of the first high frequency voltage and formation of a cavity or channel within the nucleus pulposus, a second high frequency voltage may be applied betweenactive electrode910 and returnelectrode918, wherein application of the second high frequency voltage causes coagulation of nucleus pulposus tissue adjacent to the cavity or channel. Such coagulation of nucleus pulposus tissue may lead to increased stiffness, strength, and/or rigidity within certain regions of the nucleus pulposus, concomitant with an alleviation of discogenic pain. Furthermore, coagulation of tissues may lead to necrotic tissue which is subsequently broken down as part of a natural bodily process and expelled from the body, thereby resulting in de-bulking of the disc. AlthoughFIG. 37 depicts a disc having fissures within the annulus fibrosus, it is to be understood that apparatus and methods of the invention discussed with reference toFIG. 37 are also applicable to treating other types of disc disorders, including those described with reference toFIGS. 36B,36D.

FIG. 38 showsshaft902 ofelectrosurgical probe900 within an intervertebral disc, wherein shaftdistal end902a is targeted to a specific site within the disc. In the situation depicted inFIG. 38, the target site is occupied by anerrant fragment294′ of nucleus pulposus tissue. Shaftdistal end902 may be guided or directed, at least in part, by appropriate placement ofintroducer928, such thatactive electrode910 is in the vicinity offragment294′. Preferably,active electrode910 is adjacent to, or in contact with,fragment294′. AlthoughFIG. 38 depicts a disc in which a fragment of nucleus pulposus is targeted byshaft902, the invention described with reference toFIG. 38 may also be used for targeting other aberrant structures within an intervertebral disc, including annular fissures and contained herniations. In a currently preferred embodiment,shaft902 includes at least one curve (not shown in FIG.38), and other features described herein with reference toFIGS. 26A-35, wherein shaftdistal end902a may be precisely guided by an appropriate combination of axial and rotational movement ofshaft902. The procedure illustrated inFIG. 38 may be performed generally according to the description presented with reference to FIG.37. That is,shaft902 is introduced into the disc viaintroducer928 in a percutaneous procedure. After shaftdistal end902a has been guided to a target site, tissue at or adjacent to that site is ablated by application of a first high frequency voltage. Thereafter, depending on the particular condition of the disc being treated, a second high frequency voltage may optionally be applied in order to locally coagulate tissue within the disc.

FIG. 39 schematically represents a series of steps involved in a method of ablating disc tissue according to the present invention; whereinstep1200 involves advancing an introducer needle towards an intervertebral disc to be treated. The introducer needle has a lumen having a diameter greater than the diameter of the shaft distal end, thereby allowing free passage of the shaft distal end through the lumen of the introducer needle. In one embodiment, the introducer needle preferably has a length in the range of from about 3 cm to about 25 cm, and the lumen of the introducer needle preferably has a diameter in the range of from about 0.5 cm. to about 2.5 mm. Preferably, the lumen of the introducer needle has a diameter in the range of from about 105% to about 500% of the diameter of the shaft distal end. The introducer needle may be inserted in the intervertebral disc percutaneously, e.g. via a posterior lateral approach. In one embodiment, the introducer needle may have dimensions similar to those of an epidural needle, the latter well known in the art.

Optional step1202 involves introducing an electrically conductive fluid, such as saline, into the disc. In one embodiment, in lieu ofstep1202, the ablation procedure may rely on the electrical conductivity of the nucleus pulposus itself.Step1204 involves inserting the shaft of the electrosurgical probe into the disc, e.g., via the introducer needle, wherein the distal end portion of the shaft bears an active electrode and a return electrode. In one embodiment, the shaft includes an outer shield, first and second curves at the distal end portion of the shaft, and an electrode head having an apical spike, generally as described with reference toFIGS. 26A-32.

Step1206 involves ablating at least a portion of disc tissue by application of a first high frequency voltage between the active electrode and the return electrode. In particular, ablation of nucleus pulposus tissue according to methods of the invention serves to decrease the volume of the nucleus pulposus, thereby relieving pressure exerted on the annulus fibrosus, with concomitant decompression of a previously compressed nerve root, and alleviation of discogenic pain.

In one embodiment, the introducer needle is advanced towards the intervertebral disc until it penetrates the annulus fibrosus and enters the nucleus pulposus. The shaft distal end in introduced into the nucleus pulposus, and a portion of the nucleus pulposus is ablated. These and other stages of the procedure may be performed under fluoroscopy to allow visualization of the relative location of the introducer needle and shaft relative to the nucleus pulposus of the disc. Additionally or alternatively, the surgeon may introduce the introducer needle into the nucleus pulposus from a first side of the disc, then advance the shaft distal end through the nucleus pulposus until resistance to axial translation of the electrosurgical probe is encountered by the surgeon. Such resistance may be interpreted by the surgeon as the shaft distal end having contacted the annulus fibrosus at the opposite side of the disc. Then, by use of depth markings one the shaft (FIG.32A), the surgeon can retract the shaft a defined distance in order to position the shaft distal end at a desired location relative to the nucleus pulposus. Once the shaft distal end is suitably positioned, high frequency voltage may be applied to the probe via the power supply unit.

Afterstep1206,optional step1208 involves coagulating at least a portion of the disc tissue. In one embodiment,step1206 results in the formulation of a channel or cavity within the nucleus pulposus. Thereafter, tissue at the surface of the channel may be coagulated duringstep1208. Coagulation of disc tissue may be performed by application of a second high frequency voltage, as described hereinabove. Afterstep1206 orstep1208, the shaft may be moved (step1210) such that the shaft distal end contacts fresh tissue of the nucleus pulposus. The shaft may be axially translated (i.e. moved in the direction of its longitudinal axis), may be rotated about its longitudinal axis, or may be moved by a combination of axial and rotational movement. In the latter case, a substantially spiral path is defined by the shaft distal end. Afterstep1210,steps1206 and1208 may be repeated with respect to the fresh tissue of the nucleus pulposus contacted by the shaft distal end. Alternatively, afterstep1206 orstep1208, the shaft may be withdrawn from the disc (step1212).Step1214 involves withdrawing the introducer needle from the disc. In one embodiment, the shaft and the needle may be withdrawn from the disc concurrently. Withdrawal of the shaft from the disc may facilitate exhaustion of ablation by-products from the disc. Such ablation by-products include low molecular weight gaseous compounds derived from molecular dissociation of disc tissue components, as described hereinabove. The above method may be used to treat any disc disorder in which Coblation® and or coagulation of disc tissue is indicated, including contained herniations. In one embodiment, an introducer needle may be introduced generally as described forstep1200, and a fluoroscopic fluid may be introduced through the lumen of the introducer needle for the purpose of visualizing and diagnosing a disc abnormality or disorder. Thereafter, depending on the diagnosis, a treatment procedure may be performed, e.g., according tosteps1202 through1214, using the same introducer needle as access. In one embodiment, a distal portion, or the entire length, of the introducer needle may have an insulating coating on its external surface. Such an insulating coating on the introducer needle may prevent interference between the electrically conductive introducer needle and electrode(s) on the probe.

The size of the cavity or channel formed in a tissue by a single straight pass of the shaft through the tissue to be ablated is a function of the diameter of the shaft (e.g., the diameter of the shaft distal end and active electrode) and the amount of axial translation of the shaft. (By a “single straight pass” of the shaft is meant one axial translation of the shaft in a distal direction through the tissue, in the absence of rotation of the shaft about the longitudinal axis of the shaft, with the power from the power supply turned on.) In the case of a curved shaft, according to various embodiments of the instant invention, a larger channel can be formed by rotating the shaft as it is advanced through the tissue. The size of a channel formed in a tissue by a single rotational pass of the shaft through the tissue to be ablated is a function of the deflection of the shaft, and the amount of rotation of the shaft about its longitudinal axis, as well as the diameter of the shaft (e.g., the diameter of the shaft distal end and active electrode) and the amount of axial translation of the shaft. (By a “single rotational pass” of the shaft is meant one axial translation of the shaft in a distal direction through the tissue, in the presence of rotation of the shaft about the longitudinal axis of the shaft, with the power from the power supply turned on.) To the large extent, the diameter of a channel formed during a rotational pass of the shaft through tissue can be controlled by the amount of rotation of the shaft, wherein the “amount of rotation” encompasses both the rate of rotation (e.g., the angular velocity of the shaft), and the number of degrees through which the shaft is rotated (e.g. the number of turns) per unit length of axial movement. Typically, according to the invention, the amount of axial translation per pass (for either a straight pass or a rotational pass) is not limited by the length of the shaft. Instead, the amount of axial translation per single pass is preferably determined by the size of the tissue to be ablated. Depending on the size of the disc or other tissue to be treated, and the nature of the treatment, etc., a channel formed by a probe of the instant invention may preferably have a length in the range of from about 2 mm to about 50 mm, and a diameter in the range of from about 0.5 mm to about 7.5 mm. In comparison, a channel formed by a shaft of the instant invention during a single rotational pass may preferably have a diameter in the range of from about 1.5 mm to about 25 mm.

A channel formed by a shaft of the instant invention during a single straight pass may preferably have a volume in the range of from about 1 mm³, or less, to about 2,500 mm³. More preferably, a channel formed by a straight pass of a shaft of the instant invention has a volume in the range of from about 10 mm³to about 2,500 mm³, and more preferably in the range of from about 50 mm³to about 2,500 mm³. In comparison, a channel formed by a shaft of the instant invention during a single rotational pass typically has a volume from about twice to about 15 times the volume of a channel of the same length formed during single rotational pass, i.e., in the range of from about 2 mm³to about 4,000 mm³, more preferably in the range of from about 50 mm³to about 2,000 mm³. While not being bound by theory, the reduction in volume of a disc having one or more channels therein is a function of the total volume of the one or more channels.FIG. 40 schematically represents a series of steps involved in a method of guiding the distal end of a shaft of an electrosurgical probe to a target site within an intervertabral disc for ablation of specifically targeted disc tissue, whereinsteps1300 and1302 are analogous tosteps1200 and1204 of FIG.39. Thereafter step1304 involves guiding the shaft distal end to a defined region within the disc. The specific target site may be pre-defined as a result of a previous procedure to visualize the disc and its abnormality, e.g., via X-ray examination, endoscopically, or fluoroscopically. As an example, a defined target site within a disc may comprise a fragment of the nucleus pulposus that has migrated within the annulus fibrosus (see, e.g.,FIG. 36D) resulting in discogenic pain. However, guiding the shaft to defined sites associated with other types of disc disorders are also possible and is within the scope of the invention.

Guiding the shaft distal end to the defined target site may be performed by axial and/or rotational movement of a curved shaft, as described hereinabove. Or the shaft may be steerable, for example, by means of a guide wire, as is well known in the art. Guiding the shaft distal end may be performed during visualization of the location of the shaft relative to the disc, wherein the visualization may be performed endoscopically or via fluoroscopy. Endoscopic examination may employ a fiber optic cable (not shown). The fiber optic cable may be integral with the electrosurgical probe, or be part of a separate instrument (endoscope).Step1306 involves ablating disc tissue, and is analogous to step1206 (FIG.39). Before or duringstep1306, an electrically conductive fluid may be applied to the disc tissue and/or the shaft in order to provide a path for current flow between active and return electrodes on the shaft, and to facilitate and/or maintain a plasma in the vicinity of the distal end portion of the shaft. After the shaft distal end has been guided to a target site and tissue at that site has been ablated, the shaft may be moved locally, e.g., within the same region of the nucleus pulposus, or to a second defined target site within the same disc. The shaft distal end may be moved as described herein (e.g., with reference to step1210, FIG.39). Or, according to an alternative embodiment, the shaft may be steerable, e.g., by techniques well known in the art.Steps1310 and1312 are analogous tosteps1212 and1214, respectively (described with reference to FIG.39).

It is known in the art that epidural steroid injections can transiently diminish perineural inflammation of an affected nerve root, leading to alleviation of discogenic pain. In one embodiment of the invention, methods for ablation of disc tissue described hereinabove may be conveniently performed in conjunction with an epidural steroid injection. For example, ablation of disc tissue and epidural injection could be carried out as part of a single procedure, by the same surgeon, using equipment common to both procedures (e.g. visualization equipment). Combining Coblation® and equidural injection in a single procedure may provide substantial cost-savings to the healthcare industry, as well as a significant improvement in patient care.

As alluded to hereinabove, methods and apparatus of the present invention can be used to accelerate the healing process of intervertebral discs having fissures and/or contained herniations. In one method, the present invention is useful in microendoscopic discectomy procedures, e.g., for decompressing a nerve root with a lumbar discectomy. For example, as described above in relation toFIGS. 18-20, a percutaneous penetration can be made in the patient's back so that the superior lamina can be accessed. Typically, a small needle is used initially to localize the disc space level, and a guide wire is inserted and advanced under lateral fluoroscopy to the inferior edge of the lamina. Sequential cannulated dilators can be inserted over the guide wire and each other to provide a hole from the incision to the lamina. The first dilator may be used to “palpate” the lamina, assuring proper location of its tip between the spinous process and facet complex just above the inferior edge of the lamina. A tubular retractor can then be passed over the largest dilator down to the lamina. The dilators can then be removed, so as to establish an operating corridor within the tubular retractor. It should be appreciated however, that other conventional or proprietary methods can be used to access the target interverterbral disc. Once the target intervertebral disc has been accessed, an introducer device may be inserted into the intervertebral disc.

With reference toFIG. 41, in one embodiment, bothintroducer needle928 and a second orancillary introducer938 may be inserted into the same disc, to allow introduction of anancillary device940 into the target disc viaancillary introducer938.Ancillary device940 may comprise, for example, a fluid delivery device, a return electrode, an aspiration lumen, a second electrosurgical probe, or an endoscope having an optical fiber component. Each ofintroducer needle928 andancillary introducer938 may be advanced through the annulus fibrosus until at least the distal end portion of eachintroducer928 and938, is positioned within the nucleus pulposus. Thereafter,shaft902″ ofelectrosurgical probe900′ may be inserted through at least one ofintroducers928,938, to treat the intervertebral disc. Typically,shaft902″ ofprobe900′ has an outer diameter no larger than about 7 French (1 Fr: 0.33 mm), and preferably between about 6 French and 7 French.

Prior to insertingelectrosurgical probe900 into the intervertebral disc, an electrically conductive fluid can be delivered into the disk via a fluid delivery assembly (e.g., ancillary device940) in order to facilitate or promote the Coblation® mechanism within the disc following the application of a high frequency voltage viaprobe900′. By providing a separate device (940) for fluid delivery, the dimensions ofelectrosurgical probe900 ′ can be kept to a minimum. Furthermore, when the fluid delivery assembly is positioned withinancillary introducer938, electrically conductive fluid can be conveniently replenished to the interior of the disc at any given time during the procedure. Nevertheless, in other embodiments, the fluid delivery assembly can be physically coupled toelectrosurgical probe900′.

In some methods, a radiopaque contrast solution (not shown) may be delivered through a fluid delivery assembly so as to allow the surgeon to visualize the intervertebral disc under fluoroscopy. In some configurations, atracking device942 can be positioned on shaftdistal end portion902″a. Additionally or alternatively,shaft902″ can be marked incrementally, e.g., with depth markings903, to indicate to the surgeon how far the active electrode is advanced into the intervertebral disc. In one embodiment,tracking device942 includes a radiopaque material that can be visualized under fluoroscopy. Such atracking device942 and depth markings903 provide the surgeon with means to track the position of theactive electrode910 relative to a specific target site within the disc to whichactive electrode910 is to be guided. Such specific target sites may include, for example, an annular fissure, a contained herniation, or a fragment of nucleus pulposus. The surgeon can determine the position of theactive electrode910 by observing the depth markings903, or by comparing tracking device output, and a fluoroscopic image of the intervertebral disc to a pre-operative fluoroscopic image of the target intervertebral disc.

In other embodiments, an optical fiber (not shown) can be introduced into the disc. The optical fiber may be either integral withprobe900′ or may be introduced as part of anancillary device940 viaancillary introducer938. In this manner, the surgeon can visually monitor the interior of the intervertebral disc and the position ofactive electrode910.

In addition to monitoring the position of the distal portion ofelectrosurgical probe900′, the surgeon can also monitor whether the probe is in Coblation® mode. In most embodiments, power supply28 (e.g.,FIG. 1) includes a controller having an indicator, such as a light, an audible sound, or a liquid crystal dislay (LCD), to indicate whetherprobe900′ is generating a plasma within the disc. If it is determined that the Coblation® mechanism is not occurring, (e.g., due to an insufficiency of electrically conductive fluid within the disc), the surgeon can then replenish the supply of the electrically conductive fluid to the disc.

FIG. 42 is a side view of anelectrosurgical probe900′ includingshaft902″ havingtracking device942 located atdistal end portion902″a.Tracking device942 may serve as a radiopaque marker adapted for guidingdistal end portion902″a within a disc.Shaft902″ also includes at least oneactive electrode910 disposed on thedistal end portion902″a. Preferably, electrically insulating support member orcollar916 is positioned proximal ofactive electrode910 to insulateactive electrode910 from at least onereturn electrode918. In most embodiments, thereturn electrode918 is positioned on the distal end portion of theshaft902″ and proximal of theactive electrode910. In other embodiments, however, return electrode918 can be omitted fromshaft902″, in which case at least one return electrode may be provided onancillary device940, or the return electrode may be positioned on the patient's body, as a dispersive pad (not shown).

Althoughactive electrode910 is shown inFIG. 42 as comprising a single apical electrode, other numbers, arrangements, and shapes foractive electrode910 are within the scope of the invention. For example,active electrode910 can include a plurality of isolated electrodes in a variety of shapes.Active electrode910 will usually have a smaller exposed surface area thanreturn electrode918, such that the current density is much higher atactive electrode910 than atreturn electrode918. Preferably, returnelectrode918 has a relatively large, smooth surfaces extending aroundshaft902″ in order to reduce current densities in the vicinity ofreturn electrode918, thereby minimizing damage to non-target tissue.

While bipolar delivery of a high frequency energy is the preferred method of debulking the nucleus pulposus, it should be appreciated that other energy sources (i.e., resistive, or the like) can be used, and the energy can be delivered with other methods (i.e., monopolar, conductive, or the like) to debulk the nucleus.

FIG. 43A shows a steerableelectrosurgical probe950 including ashaft952, according to another embodiment of the invention. Preferably,shaft952 is flexible and may assume a substantially linear configuration as shown.Probe950 includeshandle904, shaftdistal end952a,active electrode910, insulatingcollar916, and returnelectrode918. As can be seen inFIG. 43B, under certain circumstances, e.g., upon application of a force toshaft952 during guiding orsteering probe950 during a procedure, shaftdistal end952a can adopt a non-linear configuration, designated952′a. The deformable nature of shaftdistal end952′a allowsactive electrode910 to be guided to a specific target site within a disc.

FIG. 44 shows steerableelectrosurgical probe950 inserted within the nucleus pulposus of an intervertebral disc. Anancillary device940 andancillary introducer928 may also be inserted within the nucleus pulposus of the same disc. To facilitate the debulking of the nucleus pulposus adjacent to a contained herniation, shaft952 (FIG. 43A) can be manipulated to a non-linear configuration, represented as952′. Preferably, shaft955/952′ is flexible over at least shaftdistal end952a so as to allow steering ofactive electrode910 to a position adjacent to the targeted disc abnormality. The flexible shaft may be combined with a sliding outer shield, a sliding outer introducer needle, pull wires, shape memory actuators, and other known mechanisms (not shown) for effecting selective deflection ofdistal end952a to facilitate positioning ofactive electrode910 within a disc. Thus, it can be seen that the embodiment ofFIG. 44 may be used for the targeted treatment of annular fissures, or any other disc abnormality in which Coblation® is indicated.

In oneembodiment shaft952 has a suitable diameter and length to allow the surgeon to reach the target disc or vertebra by introducing the shaft through the thoracic cavity, the abdomen or the like. Thus,shaft952 may have a length in the range of from about 5.0 cm to 30.0 cm, and a diameter in the range of about 0.2 mm to about 20 mm. Alternatively,shaft952 may be delivered percutaneously in a posterior lateral approach. Regardless of the approach,shaft952 may be introduced via a rigid or flexible endoscope. In addition, it should be noted that the methods described with reference toFIGS. 41 and 44 may also be performed in the absence ofancillary introducer938 andancillary device940.

Although the invention has been described primarily with respect to electrosurgical treatment of intervertebral discs, it is to be understood that the methods and apparatus of the invention are also applicable to the treatment of other tissues, organs, and bodily structures. For example, the principle of the “S-curve” configuration of the invention may be applied to any medical system or apparatus in which a medical instrument is passed within an introducer device, wherein it is desired that the distal end of the medical instrument does not contact or impinge upon the introducer device as the instrument is advanced from or retracted within the introducer device. The introducer device may be any apparatus through which a medical instrument is passed. Such a medical system or apparatus may include, for example, a catheter, a cannula, an endoscope, and the like. Thus, while the exemplary embodiments of the present invention have been described in detail, by way of example and for clarity of understanding, a variety of changes, adaptations, and modifications will be obvious to those of skill in the art. Therefore, the scope of the present invention is limited solely by the appended claims.

Claims (58)

1. A method of treating an inter-vertebral disc, comprising:

a) contacting at least a first region of a nucleus pulposus of the inter-vertebral disc with at least one active electrode of an electrosurgical system, the at least one active electrode disposed on a shaft of an electrosurgical probe, and the at least one active electrode functionally coupled to a power supply unit; and

b) applying a first high frequency voltage between the at least one active electrode and at least one return electrode, wherein at least a portion of the nucleus pulposus is ablated and the volume of the nucleus pulposus is decreased .

2. The method ofclaim 1, further comprising:

c) contacting at least a second region of the nucleus pulposus of the inter-vertebral disc with the at least one active electrode, and thereafter, repeating said step b).

3. The method ofclaim 1, wherein during said step b), the at least one active electrode is translated within the nucleus pulposus, wherein a channel is formed within the nucleus pulposus, and translation of the at least one active electrode within the nucleus pulposus is implemented via movement of the probe.

4. The method ofclaim 3, wherein movement of the probe is selected from the group consisting of axial movement, rotational movement, and concurrent axial and rotational movement.

5. The method ofclaim 1, wherein said steps a) and b) result in formation of a channel within the nucleus pulposus, the channel having a channel wall, and the method further comprises:

d) positioning the at least one active electrode adjacent to the channel wall; and

e) coagulating tissue of the nucleus pulposus by applying a second high frequency voltage between the at least one active electrode and the at least one return electrode.

6. The method ofclaim 5, wherein tissue at the channel wall is coagulated, and the nucleus pulposus undergoes a physical change selected from the group consisting of stiffening, increased rigidity, increased strength, decrease in volume, and decrease in mass.

7. The method ofclaim 5, wherein the first high frequency voltage is in the range of from about 150 to about 700 volts rms, and the second high frequency voltage is in the range of from about 20 to about 150 volts rms.

8. The method ofclaim 5, wherein the first high frequency voltage is in the range of from about 150 to about 350 volts rms, and the second high frequency voltage is in the range of from about 20 to about 90 volts rms.

9. The method ofclaim 1, wherein the at least one active electrode and the at least one return electrode are disposed on a distal end of the shaft, and the at least one return electrode is spaced proximally from the at least one active electrode.

10. The method ofclaim 1, further comprising the step of:

f) prior to said step b), providing an electrically conductive fluid at the at least a first region of the nucleus pulposus.

11. The method ofclaim 10, wherein said step f) comprises applying the electrically conductive fluid to the at least one active electrode, or applying the electrically conductive fluid to the disc.

12. The method ofclaim 10, wherein the at least one active electrode and the at least one return electrode are disposed on a distal end of the shaft, and the at least one return electrode is spaced proximally from the at least one active electrode, and the electrically conductive fluid provides an electrically conductive path between the at least one active electrode and the at least one return electrode.

13. The method ofclaim 1, wherein the shaft includes a shaft distal end, and the shaft distal end is introduced into the nucleus pulposus via an introducer needle, the introducer needle includes a lumen and a needle distal end, the shaft distal end includes at least one curve therein, and the shaft distal end is retractable into the lumen without contacting the needle distal end.

14. The method ofclaim 1, wherein the shaft is visualized fluoroscopically or endoscopically.

15. The method ofclaim 1, wherein the at least one active electrode comprises an electrode head having a substantially apical spike and a substantially equatorial cusp, and the shaft includes an insulating collar located proximal to the electrode head.

16. The method ofclaim 15, wherein the insulating collar comprises a material selected from the group consisting of: a ceramic, a glass, and a silicone.

17. The method ofclaim 1, wherein the at least one active electrode includes a filament, the shaft includes a first insulating sleeve encasing the filament, a return electrode on the first insulating sleeve, and a second insulating sleeve on the return electrode.

18. The method ofclaim 1, wherein the shaft includes a shield encasing the shaft, wherein the shield decreases the amount of leakage current passing from the electrosurgical probe.

19. The method ofclaim 1, wherein the shaft includes a first curve and a second curve proximal to the first curve, the first curve and the second curve are in the same plane relative to the longitudinal axis of the shaft, and the first curve and the second curve are in different directions relative to the longitudinal axis of the shaft, the first curve is characterized by a first angle and the second curve is characterized by a second angle, wherein the first angle is less than the second angle.

20. The method ofclaim 1, wherein decreasing the volume of the nucleus pulposus relieves pressure exerted by the nucleus pulposus on an annulus fibrosus.

21. The method ofclaim 1, wherein decreasing the volume of the nucleus pulposus decompresses at least one nerve or nerve root, and discogenic pain is alleviated.

22. The method ofclaim 1, wherein during said step b), the at least one active electrode is axially translated within the nucleus pulposus to form a channel within the nucleus pulposus, wherein the channel is formed by a single straight pass of the shaft in the nucleus pulposus, and the channel has a volume in the range of from about 1 mm³to about 2,500 mm³.

23. The method ofclaim 22, wherein the channel has a volume in the range of from about 10 mm³to about 2,500 mm³.

24. The method ofclaim 22, wherein the channel has a diameter in the range of from about 0.5 mm to about 7.5 mm.

25. The method ofclaim 22, wherein the channel has a length in the range of from about 2 mm to about 50 mm.

26. The method ofclaim 1, wherein during said step b), the at least one active electrode is axially translated within the nucleus pulposus and concurrently therewith the shaft is rotated about its longitudinal axis, wherein the at least one active electrode forms a channel within the nucleus pulposus, the channel is formed by a single rotational pass of the shaft, wherein the at least one active electrode is disposed on a distal end of the shaft, the shaft includes at least one curve, and the channel has a volume in the range of from about 2 mm³to about 38,000 mm³.

27. The method ofclaim 26, wherein the channel has a volume in the range of from about 50 mm³to about 10,000 mm³.

28. The method ofclaim 1, wherein the shaft has a length in the range of from about 4 cm to about 30 cm, and the shaft has a diameter in the range of from about 0.5 mm to about 2.5 mm.

29. The method ofclaim 1, wherein the shaft includes a shaft distal end, and wherein the shaft distal end is introduced into the nucleus pulposus via an introducer needle, the introducer needle including a lumen, wherein the introducer needle has a length in the range of from about 3 cm to about 25 cm, and the lumen has a diameter in the range of from about 0.5 mm to about 2.5 mm.

30. The method ofclaim 1, wherein the method is performed percutaneously, and the at least a portion of the nucleus pulposus is ablated at a temperature in the range of from about 45° C. to about 90° C.

31. The method ofclaim 1, wherein the intervertebral disc is a lumber disc, and the shaft has a length in the range of from about 10 cm to about 25 cm.

32. The method ofclaim 1, wherein the intervertebral disc is a cervical disc, and the shaft has a length in the range of from about 4 cm to about 15 cm.

33. A method of treating an inter-vertebral disc, comprising:

providing an electrosurgical system including a probe and a power supply unit, wherein the probe includes a shaft and a handle, the shaft including a distal end portion, at least one active electrode, and at least one return electrode, the at least one active electrode located on the distal end portion of the shaft, the distal end portion of the shaft having a pre-defined bias in the longitudinal direction thereof;

inserting the distal end portion of the shaft within the disc; and

ablating at least a portion of nucleus pulposus tissue from the disc, wherein at least one channel is formed within the nucleus pulposus tissue.

34. The method ofclaim 33, wherein said ablating step comprises applying a first high frequency voltage between the at least one active electrode and the at least one return electrode, wherein a plasma is formed in the vicinity of the at least one active electrode, high molecular weight components of the nucleus pulposus tissue undergo molecular dissociation to form low molecular weight gaseous materials, and the volume of the nucleus pulposus is decreased.

35. The method ofclaim 33, wherein said ablating step comprises ablating the nucleus pulposus tissue at a temperature in the range of from about 45° C. to about 90° C.

36. The method ofclaim 33, wherein said ablating step results in the production of ablation by-products, and the ablation by-products are aspirated from the disc by a suction device.

37. The method ofclaim 34, further comprising the step of:

removing the shaft from the disc, wherein said removing step causes the low molecular weight gaseous materials to be exhausted from the disc.

38. The method ofclaim 33, wherein said ablating step causes localized ablation of targeted disc tissue with minimal collateral damage to non-target tissue within the disc.

39. The method ofclaim 33, wherein said ablating step comprises applying a first high frequency voltage between the at least one active electrode and the at least one return electrode, and the method further comprises:

after said ablating step, applying a second high frequency voltage between the at least one active electrode and the at least one return electrode, wherein the second high frequency voltage is sufficient to coagulate disc tissue adjacent to the distal end portion of the shaft.

40. The method ofclaim 33, further comprising:

before said ablating step, contacting the at least one active electrode with a quantity of an electrically conductive fluid.

41. The method ofclaim 33, wherein said insertion step comprises advancing the shaft distal end portion via an introducer needle having a lumen and a needle distal end, wherein the shaft distal end portion is advanced distally beyond the needle distal end, wherein the at least one active electrode does not make contact with the needle distal end; and the method further comprises retracting the shaft distal end portion proximally within the lumen of the introducer needle, wherein the at least one active electrode does not make contact with the needle distal end.

42. The method ofclaim 33, wherein the shaft includes a shield, the shaft distal end portion includes a first curve, a second curve proximal to the first curve, and an insulating collar distal to the first curve, and the at least one active electrode comprises a filament and a head having an apical spike and an equatorial cusp.

43. A method of treating an inter-vertebral disc with an electrosurgical system, the electrosurgical system including a probe having a shaft, the shaft including a shaft distal end portion, an active electrode disposed on the shaft distal end portion, and a return electrode disposed proximal to the active electrode, the method comprising:

a) contacting a nucleus pulposus of the disc with the active electrode;

b) applying a high frequency voltage between the active electrode and the return electrode, wherein the high frequency voltage is sufficient to ablate disc tissue; and

c) during the applying step, translating the shaft distal end portion within the nucleus pulposus, wherein tissue of the nucleus pulposus is ablated and the volume of the nucleus pulposus is decreased.

44. The method ofclaim 43, wherein the shaft distal end portion includes a first curve and a second curve proximal to the first curve, wherein the first curve allows the active electrode to be retracted within an introducer needle without contacting the introducer needle.

45. The method ofclaim 44, wherein the second curve allows the active electrode to contact fresh tissue within the nucleus pulposus when the shaft is rotated about its longitudinal axis.

46. The method ofclaim 43, wherein the active electrode includes an electrode head having a substantially equatorial cusp and an apical spike, wherein the apical spike promotes high current density at the active electrode and facilitates axial translation of the shaft distal end portion within a tissue.

47. The method ofclaim 43, wherein the method is performed percutaneously, and the shaft distal end portion is introduced into the disc via an introducer needle.

48. The method ofclaim 43, wherein decrease in the volume of the nucleus pulposus leads to decompression of a nerve root and alleviation of discogenic pain.

49. The method ofclaim 48, wherein the discogenic pain is caused by a contained herniation, an annular fissure, or fragmentation of the nucleus pulposus.

50. The method ofclaim 43, further comprising:

d) inserting an ancillary introducer needle into the disc; and

e) advancing, via the ancillary introducer needle, an ancillary device into the nucleus pulposus, wherein the ancillary device comprises an endoscope, an optical fiber, an aspiration device, a fluid delivery assembly, or a return electrode.

51. The method ofclaim 43, wherein the shaft distal end portion includes a tracking device for indicating a location of the shaft distal end portion relative to the nucleus pulposus.

52. The method ofclaim 43, wherein the shaft includes at least one depth marking for indicating a location of the shaft distal end portion relative to the nucleus pulposus.

53. The method ofclaim 43, wherein said contacting step comprises:

f) advancing the shaft distally through the nucleus pulposus until the shaft distal end portion contacts an inner wall of an annulus fibrosus; and thereafter, retracting the shaft a defined distance.

54. The method ofclaim 43, further comprising the step of:

g) determining a depth of penetration of the shaft distal end portion within the disc.

55. The method ofclaim 54, wherein the shaft distal end portion is introduced into the disc via an introducer needle having an introducer proximal end, and said step g) comprises monitoring the position of the introducer proximal end relative to a mechanical stop or at least one depth marking.

56. The method ofclaim 54, wherein said step g) comprises:

h) advancing the shaft distal end portion through the nucleus pulposus until the shaft distal end portion contacts the annulus fibrosus; and thereafter,

i) retracting the shaft distal end portion a defined distance.

57. The method ofclaim 55, wherein said step g) comprises:

h) advancing the shaft distal end portion through the nucleus pulposus until the mechanical stop contacts a proximal end of the introducer needle.

58. The method ofclaim 1 wherein the volume of the nucleus pulposus is decreased.

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