Conformal Sensor Film for Endoscopic Force Feedback
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Solution Overview
Problem
Endoscopic surgery tools face challenges in accurately assessing the force applied to tissue due to mechanical advantage changes and friction, leading to potential tissue damage and complications, and existing sensor solutions require modifications or are unreliable.
Innovation Solution
A sensor film with thin conformal substrate and sensing elements is retrofitted onto standard endoscopic instruments, allowing real-time force feedback without modifying the instrument or using specialized trocars, and is compatible with existing trocars.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If endoscopic surgery is used to reduce dissection, then patient trauma and recovery time are reduced, but the surgeon's ability to accurately assess applied force is degraded due to fulcrum effects and friction
Solution Approach 1:
The patent replaces mechanical force assessment (direct tactile feedback) with electronic sensing elements that convert mechanical stress into electrical signals. Strain gauges, piezoelectric elements, or capacitive sensors detect forces at the distal end and transmit data electronically to the surgeon, eliminating reliance on mechanical fulcrum effects and friction.
Solution Approach 2:
The patent introduces an intermediary sensing system between the surgeon's manual manipulation and the tissue interaction. Sensors mounted on the instrument shaft or end effector act as intermediaries, measuring forces independently of the trocar's mechanical effects and providing accurate data to the surgeon.
2Measurement precision
If distal sensors are coupled to the exterior of the instrument using wiring in grooves, then force sensing is enabled, but the instrument structure must be modified which increases complexity and manufacturing cost
Solution Approach 1:
The patent segments the sensing function from the structural function of the instrument. Sensors are mounted on separate elements (instrument shaft, end effector, or removable components) rather than being integrated into the instrument's core structure, allowing independent replacement and reducing modification requirements.
Solution Approach 2:
The patent employs thin-film flexible printed circuit boards or flexible substrates to mount sensing elements. These thin films can be conformally attached to the instrument surface without requiring grooves, holes, or structural modifications, enabling sensor integration while maintaining instrument integrity.
3Ease of manufacture
If a sheath with sensors is placed over the instrument, then sensing is added without modifying the instrument, but the sheath thickness prevents use with existing trocars and requires redesign
Solution Approach 1:
The patent uses extremely thin flexible substrates (thin films) to mount sensors, reducing the overall thickness to less than 1mm. This allows the sensor assembly to fit within the clearance between standard endoscopic instruments and trocars without requiring trocar redesign or instrument modification.
Solution Approach 2:
The patent transitions from a bulky three-dimensional sensor housing to a two-dimensional thin-film sensor assembly that can be conformally wrapped around the instrument shaft. This dimensional reduction enables compatibility with existing trocars while maintaining sensing functionality.
4Reliability
If sensors are built into the instrument during manufacturing or require disassembly, then reliable sensing is achieved, but the instrument cannot be easily upgraded or modified
Solution Approach 1:
The patent segments the sensing system into modular components that can be independently mounted, replaced, or upgraded. Sensors are attached to removable sections of the instrument or to the end effector itself, allowing different sensor types to be interchanged without affecting the main instrument structure or compromising reading consistency.
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
Provides accurate real-time force feedback to surgeons, reducing tissue damage and complications, and is cost-effective by allowing interchangeable sensors without needing to replace the entire instrument.
Implementation Method 1
at least one sensing element on the elongate shaft body, the at least one sensing element located adjacent to the distal end
Data Source
Figure 1~2e
Figure 3a~3d
Figure 3e~4
AI summary
An endoscopic instrument for use with a trocar, said endoscopic instrument comprising an elongate shaft body having a proximal end and a distal end; an end effector assembly at said distal end operable by manipulation of actuator mechanism at said proximal end; a substrate core having a first surface and a second surface; at least one sensing element on said first surface, said at least one sensing element located adjacent to said distal end; an electronics module for receiving sensed signals from said at least one sensing element, said electronics module located adjacent to said proximal end; a first conductive layer residing on said first surface, said first conductive layer having first solder mask coated thereon; a second conductive layer residing on said second surface, second conductive layer having a second solder mask coated thereon, and wherein said second conductive layer coupled to said at least one sensing element relays said sensed signals from said at least one sensing element to said electronics module and said a first conductive layer is grounded.