Disposable Zero-Heat-Flux Deep Tissue Temperature Probe
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Solution Overview
Problem
Existing deep tissue temperature probes are non-disposable, expensive, and prone to cross-contamination due to their size, mass, and sterilization requirements, limiting their widespread clinical adoption and increasing costs.
Innovation Solution
A disposable zero-heat-flux deep tissue temperature probe is designed with a flexible substrate supporting thermal sensors and a heater, featuring a multi-level structure that minimizes radial heat losses and is easy to fabricate, with a low profile and lightweight construction, allowing for flexible placement on the body.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Measurement precision
If traditional ZHF probe designs are used, then measurement precision is maintained, but device cost and complexity increase, and disposability is compromised
Solution Approach 1:
The probe is divided into discrete functional layers including substrate layer, thermal sensor layer, thermal resistor layer, and heater layer. Each layer performs a specific function and can be independently fabricated and assembled, reducing overall device complexity while maintaining measurement precision through optimized layer-specific designs
Solution Approach 2:
The patent implements a multi-level nested structure where thermal sensors are positioned within recesses in the substrate, thermal resistors are embedded between sensor layers, and heaters are integrated into the probe structure. This nesting approach minimizes radial heat losses by containing thermal elements within the probe body rather than exposing them externally
2Ease of manufacture
If traditional DTT probes are made reusable, then manufacturing cost is reduced, but cross-contamination risk and sterilization complexity increase
Solution Approach 1:
The patent designs the probe as a disposable single-use device with a simplified construction that eliminates the need for expensive sterilization processes. The probe incorporates inexpensive thermal sensors and a simple heater structure that can be manufactured at low cost, making disposability economically viable and eliminating cross-contamination risks between patients
Solution Approach 2:
The probe uses a low thermal mass design with thin substrate layers and minimal thermal material, enabling rapid thermal response times despite the disposable construction. This parameter optimization ensures that the simplified disposable structure maintains measurement performance comparable to reusable probes
3Loss of time
If probe size and mass are reduced, then response time and equilibrium time improve, but radial heat losses may increase
Solution Approach 1:
Thermal sensors are positioned within recesses in the substrate, and thermal resistors are embedded between sensor layers, creating a nested configuration that minimizes exposed thermal mass. This nesting reduces radial heat losses by containing thermal elements within the probe body while maintaining small overall dimensions for fast response
Solution Approach 2:
The probe uses a thin flexible substrate that provides structural support while minimizing thermal mass. The thin film construction reduces the distance for thermal conduction from the skin to the sensors, improving response time while the flexible nature allows conformal contact that reduces radial heat losses through improved coupling
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enables cost-effective, non-invasive, and disposable deep tissue temperature monitoring, reducing the risk of cross-contamination and making perioperative temperature management more accessible and affordable.
Implementation Method 1
a thermal resistor disposed between and separating the respective sections supporting the thermal sensors into strata
Implementation Method 2
a heater disposed on a periphery of the substrate
Data Source
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AI summary
A disposable, zero-heat-flux, deep tissue temperature probe (500) is constructed using a support assembly with multiple sections (502, 504, 506) folded together or separated into strata during assembly of the probe. The sections support elements of the probe, including thermal sensors and a thermal resistor (517) between the thermal sensors. Optionally, one of the sections supports a heater (514).