Microwave ablation probe with integrated temperature sensor

Abstract

The invention relates to a microwave ablation probe with an integrated temperature sensor. A microwave ablation probe includes a housing extending axially and defining a lumen, a tip positioned at a distal end of the housing, and a plurality of thermocouples integrated in the housing.

Description

TECHNICAL FIELD

[0001] The present disclosure relates to microwave ablation probes with integrated temperature sensors. BACKGROUND

[0002] Microwave ablation probes can be used in clinical treatments, such as thermal ablation treatments. In such treatments, thermal ablation can be used to destroy undesirable tissue, such as malignant cells, in the body. A microwave ablation antenna can be included in the probe and used to deliver radio frequency (RF) energy, such as microwave energy, to target tissue to heat the target tissue and destroy the target tissue. The microwave ablation antenna can be positioned inside an ablation probe, which can position the microwave ablation antenna near the target tissue.

[0003] In certain treatments, the ablation probe is directed through other tissue to the target tissue or near the tissue or body structure, with the hope that the ablation probe is not destroyed during the treatment. Thus, it is desirable to maintain a small size of the microwave ablation antenna and / or the probe. In this way, damage to tissue and other body structures that can be located near the target tissue to be destroyed can be minimized or prevented. Due to the complexity of such devices, it can be difficult to manufacture an ablation probe that is suitable for thermal ablation size. Further, it can be difficult to include multiple sensors, such as temperature sensors or thermocouples, in the ablation probe while maintaining a suitably small size or a suitably small outer diameter. Thus, there is a need for improved microwave ablation probe or needle designs that are small enough, deliver a known and repeatable ablation zone, and can include multiple temperature sensors or thermocouples. SUMMARY

[0004] The present disclosure relates to microwave ablation probes that can include multiple temperature sensors or multiple thermocouples. The microwave ablation probes can include a needle size with an outer diameter ranging from about 1 mm to 7 mm. The needle of the probes of the present disclosure can have thermocouples embedded in the outer wall or integrated in the wall of the needle. In some embodiments, the thermocouple junctions and electrical leads connected to the thermocouple junctions can be printed on the surface of the probe. In other embodiments, the thermocouple junctions and electrical leads can be shaped into one or more layers of the probe material structure.

[0005] According to some embodiments, a microwave ablation probe is provided. The microwave ablation probe can include a housing or cylindrical wall extending axially and defining an inner lumen, a tip positioned at a distal end of the housing, and a plurality of thermocouples integrated in the housing.

[0006] In one aspect, the plurality of thermocouples can be positioned in an array on the housing.

[0007] In another aspect, each of the plurality of thermocouples can be spaced apart from one another.

[0008] In another aspect, the plurality of thermocouples can be formed from a metallic ink printed on the housing.

[0009] In another aspect, the plurality of thermocouples can be integrally formed into at least one layer of the shell.

[0010] In another aspect, each of the plurality of thermocouples can include a thermocouple junction and a thermocouple lead.

[0011] In another aspect, the thermocouple junction and the thermocouple lead can be formed from a metallic ink printed on the shell.

[0012] In another aspect, the thermocouple junction can be formed from two different metallic inks.

[0013] In another aspect, the thermocouple junction can be formed into an outer layer of the shell.

[0014] In another aspect, the thermocouple lead can be formed into an inner layer of the shell.

[0015] In another aspect, the shell can include a plurality of non-longitudinally wrapped glass fiber layers and a plurality of longitudinally wrapped glass fiber layers, and the thermocouple lead can include a metallic fiber located in at least one of the plurality of longitudinally wrapped layers.

[0016] In some embodiments, a microwave ablation probe is provided. The microwave ablation probe can include a handle connected to a microwave ablation needle with an integrated thermocouple, wherein a thermocouple lead is electrically coupled to the thermocouple and the handle.

[0017] In some embodiments, a microwave ablation probe is provided. The microwave ablation probe can include a handle connected to a microwave ablation needle with an integrated thermocouple, wherein a thermocouple lead extends from the thermocouple to the handle.

[0018] In some embodiments, a microwave ablation device is provided. The microwave ablation device can include an ablation console having a microwave generator and an ablation probe coupled to the ablation console. The ablation probe can include a probe including a shell extending axially and defining an inner lumen, a tip positioned at a distal end of the shell, and a plurality of thermocouples integrated into the shell.

[0019] In some embodiments, a method of manufacturing a microwave ablation probe is provided. The method can include forming a shell extending axially and having an outer surface, and depositing a metallic ink on the outer surface of the shell to form a thermocouple.

[0020] In one aspect, the step of depositing the metallic ink can include printing the thermocouple using a print head.

[0021] In another aspect, the step of depositing the ink can include depositing two different metallic inks to form a thermocouple junction and a thermocouple lead.

[0022] In another aspect, the thermocouple wire can include a continuous electrical circuit from the thermocouple to a handle of the microwave ablation probe.

[0023] In some embodiments, a method of manufacturing a microwave ablation probe is provided. The method can include forming a plurality of longitudinal glass fiber layers and a plurality of non-longitudinal glass fiber layers to define a housing extending along a longitudinal direction, and embedding a thermocouple into the housing by applying metal fibers into at least one of the plurality of longitudinal layers and at least one of the plurality of non-longitudinal layers.

[0024] In another aspect, the thermocouple can include a thermocouple wire extending from a junction of the thermocouple to a handle of the microwave ablation probe.

[0025] In another aspect, the thermocouple wire can be formed by applying metal fibers in at least one of the plurality of longitudinal layers.

[0026] Further areas of applicability will become apparent from the description provided herein. The description and specific examples in this summary are intended for purposes of illustration only and are not intended to limit the scope of the present disclosure. BRIEF DESCRIPTION OF DRAWINGS

[0027] The features and advantages of the present disclosure will become more fully apparent from the following detailed description in conjunction with the accompanying drawings in which like numerals denote like components throughout several figures. Example embodiments are described with reference to the accompanying drawings by way of Figure One are to be considered in the context of this disclosure, wherein like numerals designate like parts and further wherein:

[0028] Figure 1 is an isometric view of an example microwave ablation device in accordance with some embodiments of the present disclosure.

[0029] Figure 2 is an example microwave ablation probe in accordance with some embodiments of the present disclosure.

[0030] Figure 3 is an illustration of an example portion of a needle including a plurality of thermocouples printed on the needle in accordance with some embodiments of the present disclosure.

[0031] Figure 4 is an illustration of an example portion of a needle including a plurality of thermocouples embedded in layers of the needle in accordance with some embodiments of the present disclosure. DETAILED DESCRIPTION

[0032] The description of the preferred embodiments should be read with reference to the accompanying drawings, which are hereby incorporated into and constitute part of this written description. While the application can be susceptible to various modifications and alternative forms, specific embodiments are shown by way of example in the drawings and will be described in detail herein. The goals and advantages of the claimed subject matter will become more fully apparent in light of the following detailed description, along with the appended claims and drawings.

[0033] It should be understood, however, that the present disclosure is not intended to be limited to the particular forms disclosed. Instead, this disclosure is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the exemplary embodiments. The terms "coupled", "coupled to", "operably coupled", "operably connected", and the like, should be construed broadly and are intended to encompass a mechanical, electrical, magnetic, optical, or other manner in which the devices or components are connected together in a manner that allows the connection to permit the relevant devices or components to operate as intended in relation to each other (e.g., communicate).

[0034] In this disclosure, the singular forms "a", "an", and "the" include plural referents unless the context clearly dictates otherwise. A reference to a particular numerical value includes that particular value unless the context clearly dictates otherwise. When a value is expressed as an approximation by use of the antecedent "about", it is understood that the particular value forms another embodiment. As used herein, "about X" (where X is a numerical value) preferably means ±10% (inclusive) of the value. For example, the phrase "about 8" preferably refers to values of 7.2 to 8.8 (inclusive). If present, all ranges are inclusive and can be combined. For example, when a range of "1 to 5" is referenced, the referenced range should be construed to include "1 to 4", "1 to 3", "1-2", "1-2 & 4-5", "1-3 & 5", "2-5", etc. Further, when a list of alternatives is affirmatively provided, such list can be construed to mean that any alternative can be excluded, e.g., by negative limitations in the claims. For example, when a range of "1 to 5" is referenced, the referenced range can be construed to include the case where 1, 2, 3, 4, or 5 are negatively excluded; thus, a reference to "1 to 5" can be construed to be "1 and 3-5, but not 2", or simply "wherein 2 is not included." It is intended that any component, element, attribute, or step affirmatively referenced in this document can be explicitly excluded in the claims, whether the component, element, attribute, or step is listed as an alternative or is referenced alone.

[0035] Turning now to Figure 1An example microwave ablation device 100 is shown in FIG. 1. In this example, the ablation device 100 includes an ablation console 102 and an ablation probe 110. In some examples, the ablation console 102 can be portable and can be positioned on a platform 108 of a stand 104 to allow the console 102 to be easily moved and positioned as needed during treatment. The console 102 can include a microwave generator that can provide a power signal that is sent to an antenna in a needle of the ablation probe 110. The power signal can be provided to the antenna through a power cable 116 that extends from the console 102 to the ablation probe 110. The power cable 116 can also provide coolant to the ablation probe 110. The coolant can be a saline solution or other coolant that can be supplied to the ablation probe 110 from a coolant reservoir 112 through a pump barrel 114 or other pumping mechanism.

[0036] During an ablation treatment, the needle of the ablation probe 110 can be positioned at or near a target tissue within a patient. A power signal can be provided from the console 102 to the ablation probe 110. The power signal can be provided to the ablation probe 110 through the power cable 116. The power signal can cause microwaves to be emitted from the antenna in the needle of the ablation probe 110. The microwaves can cause the tissue at the needle to be heated to an appropriate temperature to destroy the target tissue. A temperature sensor 106 can be positioned at or near the target tissue to measure the temperature that can be reached at or near the ablation region. In addition and as further described below, the needle or handle of the ablation probe 110 can include other thermocouples or temperature probes to provide information about the temperature of the coolant or the needle.

[0037] Referring now to FIG. 2, Figure 2 An example ablation probe 200 is shown in FIG. 2. The ablation probe 200 can be used with the microwave ablation device 100 described above. The ablation probe 200 can include a needle 202, a handle 204, and a power cable 206. The ablation probe 200 can be a disposable or single-use probe that is used during a single procedure or for a single patient. In other examples, the ablation probe 200 (or portions of the ablation probe 200) can be reused.

[0038] The needle 202 of the ablation probe 200 can be an elongated member that can be inserted into a patient at or near a target tissue. The needle 202 can be metallic, fiberglass, composite, alloy, or other rigid material. The needle 202 can be cylindrical and pointed. The needle 202 can be hollow such that various elements are positioned inside the needle 202. For example, a power line and an antenna can be located inside the needle 202. The power line can be located inside the needle 202 to deliver a power signal from a microwave generator to the antenna. A coolant line can also be positioned inside the needle to deliver coolant to a distal end of the needle 202. The coolant can be used to control the temperature of the needle 202 and / or control the size and shape of an ablation zone that can be created at the distal end of the needle 202.

[0039] The handle 204 can connect and / or operatively couple various aspects of the ablation probe 200 from the power supply cable 206 to the needle 202. The power supply cable 206 can include a power line that delivers a power signal from a microwave generator. The power supply cable 206 can also include a coolant supply line and a coolant return line. The coolant supply line can deliver coolant to the needle 202 and the coolant return line can transport coolant away from the needle 202 after the coolant has been used to cool the needle 202. The power supply cable 206 can also include one or more wires that can provide signals from one or more temperature sensors, thermocouples, flow sensors, or other sensors that can provide information about operational characteristics of the ablation probe 200.

[0040] The power supply cable 206 can be an elongated tube or conduit and each of the power line, the coolant supply line, the coolant return line, and other wires and lines can extend within an outer housing of the power supply cable 206. The length of the power supply cable 206 can allow a user of the ablation probe 200 to position the needle 202 of the ablation probe 200 as needed and allow a patient to be moved into and / or out of an imaging device during treatment. For example, a CT, MRI, ultrasound, or other imaging device can be used to determine the position of the needle 202 before, during, or after treatment. Accordingly, the power supply cable 206 can be long enough to allow these diagnostic procedures to be performed. In some examples, the length of the power supply cable 206 is at least 12 feet. In other examples, the length of the power supply cable 206 is at least 10 feet. In other examples, other lengths can be used.

[0041] The handle 204 can connect and / or operably couple the power cable 206 to the needle 202. Power signals, coolant, and / or sensor signals can be delivered or carried from the power cable 206 through the handle 204 to the needle 202. The handle 204 can include a housing that can enclose various aspects such as fluid connections, electrical connections, electrical components, etc. The handle 204 can be configured to orient the needle 202 at a desired alignment relative to the longitudinal axis of the power cable 206. In the illustrated example, the handle 204 is a right angle handle. The handle 204 orients the needle 202 at about 90 degrees (or substantially perpendicular) to the longitudinal axis of the power cable 206. In other examples, the handle 204 can orient the needle 202 at different angles relative to the longitudinal axis of the power cable 206.

[0042] The needle 202 can include a plurality of temperature sensors positioned at different locations. In this example, the needle includes a plurality of thermocouples 208 positioned at different axial locations along the outer surface of the needle 202. The microwave ablation probe 200 can also include other temperature sensors or other thermocouples positioned in the handle 204 and / or inside the needle 202. The thermocouples 208 can be positioned on the outer surface 210 of the needle 202 to measure temperature at different axial locations. The temperature measurements can be used to determine an ablation zone created when microwaves are emitted during operation of the probe 200. The thermocouples 208 can measure different temperatures at axial locations or can be configured at measurement points that can locally measure temperature at a particular point along the axial surface 210 and at a particular peripheral location.

[0043] The thermocouples 208 can be electrically coupled to the handle 204 and / or to the power cable 206 via the handle 204. The thermocouples 208 can provide measurement data regarding the temperature of the needle 202 to the ablation console 102. The console 102 in turn can utilize the measurement data and / or display the measurement data to a user. The thermocouples 208 can be electrically coupled to the ablation probe 200 and / or other aspects of the ablation device 100 by electrical leads or wires. The measurement data can be provided through the electrical leads. In some examples, the electrical leads can be positioned on the outer surface 210 of the needle 202. In other examples, the electrical leads can be integrated into the needle 202. In still other examples, the electrical leads can be positioned on an inner surface of the needle 202 or in an inner lumen of the needle 202.

[0044] Turning now to Figure 3 An example needle 300 is shown. The needle 300 can be used in the microwave ablation probe 200 described previously. A portion of the needle 300 is shown, but it should be understood that the needle 300 can extend from a handle of a microwave ablation probe. Further, the needle 300 is shown without other internal elements that can be included in a microwave ablation probe, such as power lines with antennas and coolant conduits.

[0045] The needle 300 can include a housing 302 and a tip 304. The housing 302 can be formed of a suitable material and can extend axially to define an internal cavity 306. The housing 302 can be formed of, for example, a fiberglass material. In other examples, the housing 302 can be formed of a plurality of different materials that are joined together. The housing 302 at or near the tip 304 is formed of a non-metallic or non-conductive material such that the housing 302 does not interfere with the microwaves emitted by an antenna located in the internal cavity 306 at or near the tip 304.

[0046] The tip 304 can be positioned at a distal end of the housing 302. The tip 304 can be a front end of the needle 300 when the needle 300 is inserted into a patient at or near a target tissue. The tip can also be formed of a non-metallic or non-conductive material. The tip 304 can be formed of a non-metallic or non-conductive material so as to not interfere with the microwaves generated at an antenna located in the internal cavity 306 of the housing 302. In some examples, the tip 304 can be formed of a ceramic material. In other examples, other materials can be used.

[0047] The needle 300 can also include a plurality of thermocouples embedded in or integrated into the housing 302. The term embedded can be used in the present disclosure to describe a thermocouple that is integrally formed with, integrally formed into, or integrally formed on the housing 302. In embodiments where the thermocouples are integrated into the housing 302, the thermocouples are built into the housing or produced as part of the housing 302. The thermocouples of the present disclosure are not produced separately from the housing 302 and then attached, assembled, or connected to the housing 302. The thermocouples of the present disclosure are not standalone devices that can be used without the housing 302. The thermocouples of the present disclosure can be embedded or integrated on the housing 302 using various processes or techniques that will be further described below. In various embodiments of the present disclosure, the thermocouples can be embedded by printing the thermocouples on the housing 302 using a metallic or conductive ink. In other embodiments of the present disclosure, the thermocouples can be embedded by, for example, forming the thermocouples into one or more layers of mutually applied materials during the formation of the fiberglass housing 302.

[0048] In the illustrated example, the housing 302 can include a first thermocouple 308, a second thermocouple 310, a third thermocouple 312, and a fourth thermocouple 314. Each thermocouple can be positioned at a different location on the housing 302. The thermocouples can be used to determine a temperature at or near each thermocouple on the housing 302. Each thermocouple can include a thermocouple junction and a thermocouple lead. The thermocouple junction can include two different metallic materials or conductive materials that are joined together. A voltage generated by the junction of the two different conductive materials can be used to determine a temperature at the location of the thermocouple junction. The thermocouple lead can extend from the thermocouple junction and can be used to measure the voltage at a location away from the thermocouple junction. The two different metals can be any suitable pair of different conductive materials, such as chromel-constantan, iron-constantan, chromel-alumel, nichrome-nisil, copper-constantan, or other pairs of conductive materials known to those skilled in the art.

[0049] The thermocouple leads can extend from each of the first thermocouple 308, the second thermocouple 310, the third thermocouple 312, and the fourth thermocouple 314. In this example, a first thermocouple lead 318 can be electrically coupled to the first thermocouple 308 and can extend from the first thermocouple 308 to an electrical wire, electrical bus, or other electrical component in the handle 204 of the microwave ablation probe 200. A second thermocouple lead 320 can be electrically coupled to the second thermocouple 310 and can extend from the second thermocouple 310 to an electrical wire, electrical bus, or other electrical component in the handle 204 of the microwave ablation probe 200. A third thermocouple lead 322 can be electrically coupled to the third thermocouple 312 and can extend from the third thermocouple 312 to an electrical wire, electrical bus, or other electrical component in the handle 204 of the microwave ablation probe 200. A fourth thermocouple lead 324 can be electrically coupled to the fourth thermocouple 314 and can extend from the fourth thermocouple 314 to an electrical wire, electrical bus, or other electrical component in the handle 204 of the microwave ablation probe 200. Although four thermocouples are illustrated in this example, it should be understood that the needle 300 can include more or less than four thermocouples and can be arranged in different patterns or arrays along the housing 302.

[0050] The thermocouples and thermocouple leads can be printed onto the surface of the housing 302 using a metallic ink or conductive ink. The metallic ink can include the different conductive materials described previously. The metallic ink can be deposited by a suitable printhead. In one example, the metallic ink can be deposited in a liquid form and allowed to harden or cure. In other examples, a piezoelectric printhead can be used to deposit the metallic ink.

[0051] Reference is now made to Figure 4Another example needle 400 is shown in FIG. 4. For purposes of illustration, a portion of needle 400 is shown. Needle 400 can be similar to needle 300 previously described in that needle 400 includes a housing 402 and a tip 404. Housing 402 can define an internal cavity 406 in which other elements of a microwave ablation probe, such as a power wire having a microwave antenna and a coolant conduit (not shown), can be positioned. In this example, housing 402 can include thermocouples embedded in housing 402 using a process that is different from the printing process previously described.

[0052] In the example shown, housing 402 can include a first thermocouple 408, a second thermocouple 410, a third thermocouple 412, and a fourth thermocouple 414. The thermocouples can include thermocouple junctions of different conductive materials as previously described as well as thermocouple wires electrically coupled to the thermocouples that are used to measure voltage at locations away from the thermocouples to determine temperature. In this example, the thermocouple junctions and thermocouple wires can be integrally formed into housing 402 during manufacture of housing 402.

[0053] In this example, housing 402 can be formed by applying a plurality of layers of glass fibers 430 to one another. The plurality of layers of glass fibers can be applied to one another to build up housing 402. Each layer can include glass fibers that are oriented in different directions relative to one another. By orienting the fibers in different directions, the strength of the overall housing 402 is improved as compared to a structure in which all of the fibers are oriented in the same direction. In some examples, housing 402 is formed using layers of fibers that are oriented in the longitudinal direction (i.e., axial, substantially parallel to the axis of needle 402) and then applying layers of fibers that are not longitudinal (e.g., radially oriented fibers, diagonally oriented fibers, helically oriented fibers, etc.) onto the longitudinal layers. The plurality of layers 430 are applied to one another in an alternating fashion to create housing 402.

[0054] During such a process of manufacturing the shell 402, metal fibers or conductive fibers or material can be deposited in one or more layers 430 to form thermocouples and / or thermocouple leads. The thermocouple leads 418, 420, 422, 424, 426, and 428 are shown at the end of the needle 402. The thermocouple leads 418, 420, 422, 424, 426, and 428 can be formed by using fibers or filaments of metal or conductive material and by applying such fibers or filaments during the formation of the longitudinal glass fiber layers, during the formation of the shell 402. In this manner, the leads 418, 420, 422, 424, 426, and 428 can extend along the longitudinal length of the shell 402 and can electrically couple one of the thermocouples 408, 410, 412, 414 to the handle 204 of the microwave ablation probe 200. The thermocouple leads 418, 420, 422, 424, 426, and 428 can be positioned in and / or formed by inner layers (i.e., not exposed to the exterior of the shell 402) and the thermocouple junctions can be shaped in outer layers of the shell 402.

[0055] The following is a list of non-limiting illustrative embodiments disclosed herein:

[0056] Illustrative Embodiment 1 : A microwave ablation probe comprising: a shell extending axially and defining an internal lumen; a tip positioned at a distal end of the shell; and a plurality of thermocouples integrated into the shell.

[0057] Illustrative Embodiment 2: The microwave ablation probe according to illustrative embodiment 1, wherein the plurality of thermocouples are positioned on the shell in an array.

[0058] Illustrative Embodiment 3: The microwave ablation probe according to any of illustrative embodiments 1 or 2, wherein each of the plurality of thermocouples are spaced apart from one another.

[0059] Illustrative Embodiment 4: The microwave ablation probe according to any of illustrative embodiments 1 to 3, wherein the plurality of thermocouples comprise a metal ink printed on the shell.

[0060] Illustrative Embodiment 5: The microwave ablation probe according to any of illustrative embodiments 1 to 3, wherein the plurality of thermocouples are integrally shaped into at least one layer of the shell.

[0061] Illustrative Embodiment 6: The microwave ablation probe according to any of illustrative embodiments 1 to 5, wherein each of the plurality of thermocouples comprises a thermocouple junction and a thermocouple lead.

[0062] Illustrative Embodiment 7: The microwave ablation probe according to illustrative embodiment 6, wherein the thermocouple junction and the thermocouple lead comprise a metal ink printed on the shell.

[0063] Illustrative Embodiment 8: The microwave ablation probe according to any of Illustrative Embodiments 6 or 7, wherein the thermocouple junction comprises two different metal inks.

[0064] Illustrative Embodiment 9: The microwave ablation probe according to Illustrative Embodiment 6, wherein the thermocouple junction is shaped into an outer layer of the shell.

[0065] Illustrative Embodiment 10: The microwave ablation probe according to any of Illustrative Embodiments 6 or 9, wherein the thermocouple wire is shaped into an inner layer of the shell.

[0066] Illustrative Embodiment 11 : The microwave ablation probe according to any of Illustrative Embodiments 6, 9, or 10, wherein the shell comprises a plurality of non-longitudinally wrapped glass fiber layers and a plurality of longitudinally wrapped glass fiber layers, and the thermocouple wire comprises metal fibers located in at least one of the plurality of longitudinally wrapped layers.

[0067] Illustrative Embodiment 12: A microwave ablation probe comprising a handle connected to a microwave ablation needle according to Illustrative Embodiment 6, wherein the thermocouple wire is electrically coupled to the thermocouple and the handle.

[0068] Illustrative Embodiment 13: A microwave ablation apparatus comprising: an ablation console comprising a microwave generator; and an ablation probe coupled to the ablation console, the ablation probe comprising a probe comprising: a shell extending axially and defining an inner lumen; a tip positioned at a distal end of the shell; and a plurality of thermocouples integrated within the shell.

[0069] Illustrative Embodiment 14: A method of manufacturing a microwave ablation probe comprising: forming a shell extending axially and having an outer surface; and depositing a metal ink on the outer surface of the shell to form a thermocouple.

[0070] Illustrative Embodiment 15: The method according to Illustrative Embodiment 14, wherein the step of depositing the metal ink comprises printing the thermocouple using a print head.

[0071] Illustrative Embodiment 16: The method according to Illustrative Embodiment 15, wherein the step of depositing the ink comprises depositing two different metal inks to form a thermocouple junction and a thermocouple wire.

[0072] Illustrative Embodiment 17: The method according to Illustrative Embodiment 16, wherein the thermocouple wire comprises a continuous electrical circuit from the thermocouple to a handle of the microwave ablation probe.

[0073] Illustrative Embodiment 18: A method of manufacturing a microwave ablation probe, comprising: forming a plurality of longitudinal glass fiber layers and a plurality of non-longitudinal glass fiber layers to define a housing extending along a longitudinal direction; and embedding a thermocouple in the housing by applying metal fibers into at least one of the plurality of longitudinal layers and at least one of the plurality of non-longitudinal layers.

[0074] Illustrative Embodiment 19: The method according to Illustrative Embodiment 18, wherein the thermocouple includes a thermocouple wire extending from a thermocouple junction to a handle of the microwave ablation probe.

[0075] Illustrative Embodiment 20: The method according to Illustrative Embodiment 19, wherein the thermocouple wire is formed by applying the metal fibers into at least one of the plurality of longitudinal layers.

[0076] The foregoing is for illustrative purposes, to exemplify, explain and describe the embodiments of the disclosure. It will be apparent to those skilled in the art that modifications and variations can be made in these embodiments without departing from the scope or spirit of the disclosure.

Claims

1. A microwave ablation probe comprising: a shell extending axially and defining an internal lumen; a tip positioned at a distal end of the shell; and a plurality of thermocouples integrated into the shell. The plurality of thermocouples are positioned on the shell in an array.

2. The microwave ablation probe of claim 1, wherein, Each of the plurality of thermocouples are spaced apart from one another.

3. The microwave ablation probe of claim 1, wherein, The plurality of thermocouples comprise a metallic ink printed on the shell.

4. The microwave ablation probe of claim 1, wherein, The plurality of thermocouples are integrally formed into at least one layer of the shell.

5. The microwave ablation probe of claim 1, wherein, Each of the plurality of thermocouples comprises a thermocouple junction and a thermocouple lead.

6. The microwave ablation probe of claim 1, wherein, The thermocouple junction and the thermocouple lead comprise a metallic ink printed on the shell.

7. The microwave ablation probe of claim 6, wherein, The thermocouple junction comprises two different metallic inks.

8. The microwave ablation probe of claim 7, wherein, The thermocouple junction is formed into an outer layer of the shell.

9. The microwave ablation probe of claim 6, wherein, The thermocouple lead is formed into an inner layer of the shell.

10. The microwave ablation probe of claim 9, wherein, The shell comprises a plurality of non-longitudinally wrapped glass fiber layers and a plurality of longitudinally wrapped glass fiber layers, and the thermocouple lead comprises metallic fibers located in at least one of the plurality of longitudinally wrapped layers.

11. The microwave ablation probe of claim 6, wherein, The thermocouple lead electrically couples the thermocouple with the handle.

12. A microwave ablation probe comprising a handle connected to the microwave ablation needle of claim 6, wherein, 13. A microwave ablation apparatus comprising: an ablation console comprising a microwave generator; and an ablation probe coupled to the ablation console, the ablation probe comprising: a shell extending axially and defining an internal lumen; a tip positioned at a distal end of the shell; and a plurality of thermocouples integrated into the shell.

14. A method of manufacturing a microwave ablation probe comprising: forming a shell, the shell extending axially and having an outer surface; and integrating a thermocouple on a surface of the shell or in the shell to form a thermocouple. The step of integrating the thermocouple comprises printing a thermocouple with a metallic ink using a print head. The step of printing the thermocouple comprises depositing two different metallic inks to form a thermocouple junction and a thermocouple lead.

15. The method of claim 14, wherein, The thermocouple lead comprises a continuous electrical circuit from the thermocouple to a handle of a microwave ablation probe.

16. The method of claim 15, wherein, The step of integrating the thermocouple comprises embedding the thermocouple in the shell by applying metallic fibers into at least one of the plurality of longitudinal layers and at least one of the plurality of non-longitudinal layers.

17. The method of claim 16, wherein, The thermocouple comprises a thermocouple lead extending from a thermocouple junction to a handle of a microwave ablation probe.

18. The method of claim 14, wherein, The thermocouple lead is formed by applying metallic fibers into at least one of the plurality of longitudinal layers.

19. The method of claim 18, wherein, ​ 20. The method of claim 19, wherein, ​

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