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