Electrode Support Thermal Insulation via Plastic Injection
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Solution Overview
Problem
Existing surgical instruments for electrosurgical applications face challenges in achieving a reliable mechanical and electrical connection between electrode plates and supports while minimizing heat transfer, which can lead to tissue damage during procedures, especially near sensitive tissues.
Innovation Solution
The surgical instrument features a seamless connection between the electrode support and plate via webs made of the same material, with a design that maximizes heat resistance by minimizing web dimensions and length, and using plastic injection to enhance mechanical connection and thermal insulation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the electrode support and electrode plate are connected via welded seams, then a reliable mechanical and electrical connection is achieved, but heat transfer between the electrode and support is limited due to small seam dimensions
Solution Approach 1:
The connection between electrode support and electrode plate is segmented into multiple discrete welding points instead of a continuous seam. This segmentation reduces the total heat transfer path while maintaining mechanical and electrical connectivity at each discrete point, thereby limiting heat flow from the heated electrode to the cooler support structure.
Solution Approach 2:
A plastic coating is applied to the electrode support as an intermediary thermal barrier. This plastic layer has low thermal conductivity and is positioned between the metal support and the electrode, reducing heat transfer from the electrode through the support while allowing the welding connections to maintain electrical continuity.
2Object-affected harmful factors
If the electrode support is kept cool to prevent tissue damage, then safety near sensitive tissues is improved, but the mechanical connection between electrode and support must be maintained
Solution Approach 1:
The plastic coating serves as a thermal intermediary that insulates the metal support from the heated electrode, keeping the support cool to prevent tissue damage. The welding connections provide localized thermal bridges that maintain mechanical strength while the overall plastic coating maintains thermal insulation.
Solution Approach 2:
The electrode assembly uses a composite structure combining metal (for electrical conductivity and mechanical strength) and plastic coating (for thermal insulation). This composite design allows the structure to simultaneously maintain mechanical integrity through the metal welding points while providing thermal protection through the plastic insulation layer.
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
This design keeps the electrode support cool during tissue treatment, reducing the risk of tissue damage and enabling precise application of current, even in challenging surgeries near sensitive tissues.
Implementation Method 1
the heat transfer resistance from the electrode plate to the electrode support can be maximized... when a plastic, which is injected into the slit between the electrode support and the electrode plate, supports the mechanical connecting effect of the webs or also takes it over to a large extent
Implementation Method 2
The preferred material thereby comprises sufficient electrically conductive characteristics, so that current can be applied to tissue by means of the electrode plate
Data Source
AI summary
A branch of an instrument comprising a metal part, which is embodied in one piece seamlessly, which comprises the electrode support as well as the electrode plate and connection webs. Preferably, this metal part is produced in an additive production method, for example selective laser melting (SLM). The branches are suitable for instruments for open surgery as well as for laparoscopic and flexible endoscopic instruments.