Embedded Sensor Electrosurgical Blade for Real-Time Monitoring

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Solution Overview

Problem

Existing monopolar electrosurgical devices have limited information regarding operating conditions during procedures, leading to suboptimal performance in terms of tissue removal, blood loss, smoke generation, thermal spreading, and scarring.

Innovation Solution

Incorporation of sensors into the electrosurgical blade to monitor operational conditions during procedures, allowing for real-time feedback and adjustments to improve the electrosurgical process.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Measurement precision

If sensors are embedded in the electrosurgical blade, then measurement precision and control of operational conditions are improved, but device complexity increases

Engineering Contradiction:

Improvemonitoring of operational conditionsVSAvoidstructure of electrosurgical electrode

Core Design Contradiction:

Measurement precisionVSDevice complexity

Solution Approach 1:

The sensor is embedded within the electrosurgical blade structure, with the sensor positioned between insulating layers that are integrated into the blade assembly. This nesting approach allows the sensor to be housed within the existing blade geometry without requiring separate external mounting structures, thereby improving measurement precision while minimizing increases in overall device complexity.

Inventive Principle:

Principle #7Nested doll (Nesting)

2Productivity

If real-time sensing is implemented, then productivity and effectiveness of electrosurgical procedures are improved, but loss of time for data processing and feedback increases

Engineering Contradiction:

Improveeffectiveness of electrosurgical proceduresVSAvoidtime for real-time feedback processing

Core Design Contradiction:

ProductivityVSLoss of time

Solution Approach 1:

The sensor provides real-time monitoring of operational conditions during electrosurgical procedures, enabling immediate feedback on parameters such as tissue impedance, temperature, or power delivery. This feedback mechanism allows the system to dynamically adjust electrosurgical energy delivery to optimize cutting, coagulation, or sealing effectiveness, thereby improving procedural productivity while maintaining real-time responsiveness through continuous monitoring rather than batch processing.

Inventive Principle:

Principle #23Feedback

3Reliability

If embedded sensors are added to monitor operational conditions, then reliability of electrosurgical procedures is improved, but ease of manufacture decreases

Engineering Contradiction:

Improvecontrol of energy deliveryVSAvoidfabrication of electrosurgical electrode

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

The sensor and insulating layers are integrated into the electrosurgical blade during the manufacturing process, with the sensor positioned between insulating layers that are formed as part of the blade assembly. This preliminary integration ensures proper sensor placement and protection before the blade undergoes final assembly and sterilization, thereby improving reliability of energy delivery monitoring while facilitating manufacturing through coordinated fabrication steps rather than post-assembly integration.

Inventive Principle:

Principle #10Preliminary action

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

Enhances the precision and effectiveness of electrosurgical procedures by providing real-time data for better control of energy delivery, reducing tissue damage and improving patient outcomes.

Implementation Method 1

As the electric current passes through the tissue, an impedance of the tissue converts a portion of the electric current into thermal energy (e.g., via the principles of resistive heating), which increases a temperature of the tissue and induces modifications to the tissue

Methodology Applied

Scientific EffectResistive heating: Joule Heating

Implementation Method 2

sensing, using the first electrode sensor, a condition related to the electrosurgical operation

Methodology Applied

Scientific EffectTemperature sensing: Thermocouple

Data Source

PatentUS20240325069A1Electrosurgical Devices Having Embedded Sensors, Methods of Use, and Methods of Manufacture

Publication Date: 2024.10.03 STRYKER EUROPEAN OPERATIONS LIMITED

AI summary

In an example, a monopolar electrosurgical electrode includes an electrosurgical substrate including an electrically conductive material extending in an axial direction from a proximal end to a distal end. The electrosurgical substrate includes an electrosurgical blade. The electrosurgical blade includes (i) a first lateral surface, (ii) a second lateral surface opposite the first lateral surface, (iii) a first major surface extending between the first lateral surface and the second lateral surface on a first side of the electrosurgical blade, and (iv) a second major surface extending between the first lateral surface and the second lateral surface on a second side of the electrosurgical blade that is opposite the first side. The monopolar electrosurgical electrode also includes a first electrode sensor embedded between a plurality of electrical insulation layers on the first major surface of the electrosurgical blade.