Insulative Spacer Design for Electrosurgical Electrode Isolation

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Solution Overview

Problem

There is a need for improved electrically insulative spacers in electrosurgical instruments that are durable, facilitate manufacturing, and provide a robust configuration for maintaining a large exposed area between opposing electrodes to prevent short circuits and arcing.

Innovation Solution

The use of insulative spacers made from high-strength materials like metal or ceramic, with a body portion embedded into the electrode and a head portion protruding beyond the working surface, providing mechanical interlocking for retention and enhancing durability, and hard anodizing for increased dielectric strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If traditional insulative spacers are used to maintain separation between opposing electrodes, then short circuits and arcing are prevented, but the spacers lack durability and mechanical strength

Engineering Contradiction:

Improvedurability of spacersVSAvoidelectrical insulation performance

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent applies composite materials by combining metal (providing strength and durability) with electrically insulative coating or ceramic material (providing electrical insulation). This creates a composite spacer structure that simultaneously achieves high mechanical strength and reliable electrical insulation, resolving the contradiction between durability and insulation performance.

Inventive Principle:

Principle #40Composite materials

2Strength

If spacers are made from durable high-strength materials, then mechanical strength and durability are improved, but manufacturing complexity increases

Engineering Contradiction:

Improvedurability of spacersVSAvoidmanufacturing complexity

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

The patent segments the spacer into two functional parts: a metal body portion (embedded in electrode) and a head portion (protruding with insulative coating or ceramic material). This segmentation allows each part to be manufactured separately using appropriate processes, then assembled together, reducing overall manufacturing complexity while maintaining high durability.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

By using composite materials with metal providing structural strength and insulative coating or ceramic providing electrical properties, the design achieves high durability through material selection rather than complex geometry, simplifying manufacturing while maintaining strength.

Inventive Principle:

Principle #40Composite materials

3Strength

If spacers are designed with body portion embedded in electrode and head portion protruding, then retention and durability are enhanced, but device complexity increases

Engineering Contradiction:

Improveretention of spacersVSAvoidspacer configuration

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The spacer is segmented into a body portion (embedded) and head portion (protruding), where each segment serves a specific function. The body portion provides mechanical anchoring within the electrode, while the head portion provides electrical insulation and maintains electrode separation. This functional segmentation enhances retention and durability without requiring overly complex overall design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

Different portions of the spacer have different properties: the body portion is made of metal for mechanical strength and embedding, while the head portion has insulative coating or ceramic material for electrical insulation. This local differentiation of material properties optimizes performance while keeping the overall structure relatively simple.

Inventive Principle:

Principle #3Local quality

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 effectively maintains electrode separation, prevents short circuits and arcing, and enhances the durability of the electrode assemblies, ensuring reliable operation in electrosurgical instruments.

Implementation Method 1

hard anodizing for increased dielectric strength

Methodology Applied

Scientific EffectHard anodizing: Anodising

Data Source

PatentUS11040189B2Electrode assemblies with electrically insulative electrode spacers, and related devices, systems, and methods

Publication Date: 2021.06.22 INTUITIVE SURGICAL OPERATIONS INC

AI summary

An electrode assembly may include an electrode support made of a first electrically insulative material and an electrode on the electrode support, the electrode having a working surface extending generally transverse to a thickness of the electrode. The electrode assembly may further include an insulative spacer retained in the electrode and made of a second electrically insulative material. The second electrically insulative material may be different from the first electrically insulative material. The insulative spacer of the electrode assembly may have a body portion extending into the thickness of the electrode, and a head portion protruding beyond the working surface of the electrode.