Ablation Electrode Thermal Via Structure for Better Heat Evacuation

The electrode is segmented into multiple functional layers including a flexible substrate, inner conductive metal layer, outer conductive metal layer, and multiple channels (irrigation channels, thermal vias, concave channels). This segmentation allows each layer to perform its specific function optimally while collectively achieving high heat transfer efficiency.

Different regions of the electrode have different properties: the concave channels provide enhanced thermal conduction pathways, the irrigation channels facilitate fluid flow, and the biocompatible outer layer ensures safety. This local differentiation of properties optimizes heat transfer at each location while managing overall complexity.

The electrode structure uses asymmetric channel designs including concave channels with varying cross-sections and irrigation channels with specific geometries. This asymmetry creates optimized flow patterns and thermal conduction pathways that enhance heat evacuation efficiency while minimizing thermal resistance.

The electrode incorporates three-dimensional concave channels and multi-layer structures that add dimensional complexity to heat transfer pathways. This dimensional approach creates multiple thermal conduction routes through the electrode thickness, reducing thermal resistance and improving heat evacuation.

The flexible substrate is prepared with pre-formed channels and layered structures before final electrode assembly. The concave channels are created in the substrate prior to adding conductive layers, allowing for more straightforward manufacturing of complex thermal pathways.

The use of a flexible substrate enables the creation of concave channels and complex geometries through bending and forming operations rather than complex machining. This flexible film approach simplifies manufacturing of three-dimensional thermal conduction pathways.