Flexible Circuit Electrode for Electrosurgical Instruments
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Solution Overview
Problem
Existing medical devices used for grasping and sealing tissue with electrical energy face challenges due to bulky conductive elements that are difficult to route through limited surgical instrument spaces, lacking efficient flexible circuit solutions.
Innovation Solution
A method of manufacturing flexible circuit electrode assemblies by laminating a conductive sheet with an insulative sheet, forming electrodes, and creating insulative layers to prevent shorting and enhance tissue grasping, using materials like copper, gold, and polyimide, and configuring them for bipolar electrosurgical instruments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If bulky conductive elements are used to deliver electrical energy, then electrical energy delivery is achieved, but the elements are cumbersome and difficult to route through limited surgical instrument spaces
Solution Approach 1:
The patent replaces bulky rigid conductive elements with flexible thin-film circuit boards that can be easily routed through limited surgical instrument spaces. The flexible circuit electrode assembly includes a thin flexible circuit board with conductive traces that can bend and conform to the instrument's limited space requirements while still delivering electrical energy effectively.
Solution Approach 2:
The patent uses composite material construction by laminating conductive sheets with insulative sheets to create a flexible circuit electrode assembly. This composite structure combines the electrical conductivity needed for energy delivery with the flexibility and compact size required for maneuverability within surgical instruments.
2Use of energy by moving object
If conductive elements are made larger to ensure proper electrical contact, then electrical energy delivery is improved, but the elements become awkward to route through limited space
Solution Approach 1:
The patent employs thin-film flexible circuit boards that maintain adequate electrical contact area while occupying minimal volume. The flexible circuit electrode assembly uses thin conductive traces and flexible substrates that provide sufficient electrical contact for energy delivery without the bulkiness of traditional rigid conductive elements.
Solution Approach 2:
The patent creates a composite structure by laminating thin conductive sheets with thin insulative sheets, resulting in a flexible circuit electrode assembly that achieves proper electrical contact with reduced volume. This layered composite approach allows for compact sizing while maintaining electrical performance.
3Stability of the object's composition
If traditional rigid conductive elements are used, then structural stability is maintained, but the elements cannot be easily integrated into flexible surgical instruments
Solution Approach 1:
The patent replaces rigid conductive elements with flexible thin-film circuit boards that can be integrated into flexible surgical instruments. The flexible circuit electrode assembly uses flexible substrates and thin conductive traces that can bend and conform while maintaining electrical functionality, enabling integration with flexible instrument designs.
Solution Approach 2:
The patent uses composite material construction with laminated conductive and insulative sheets to create a flexible circuit electrode assembly that combines structural stability with flexibility. This composite structure maintains electrical integrity and mechanical stability while allowing integration into flexible surgical instruments.
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 flexible circuit electrode assemblies enable efficient energy delivery and tissue sealing with improved flexibility and reduced bulk, allowing for precise control and effective grasping within confined surgical spaces.
Implementation Method 1
laminating a flexible electrically conductive sheet to a flexible electrically insulative sheet with an adhesive therebetween to produce a flexible laminate
Implementation Method 2
forming at least one electrically insulative layer on a tissue contacting surface of the least one electrode
Data Source
AI summary
The disclosure provides a method of manufacturing a flexible circuit electrode assembly and an apparatus manufactured by said method. According to the method, an electrically conductive sheet is laminated to an electrically insulative sheet. An electrode is formed on the electrically conductive sheet. An electrically insulative layer is formed on a tissue contacting surface of the electrode. The individual electrodes are separated from the laminated electrically insulative sheet and the electrically conductive sheet. In another method, a flexible circuit is vacuum formed to create a desired profile. The vacuum formed flexible circuit is trimmed. The trimmed vacuum formed flexible circuit is attached to a jaw member of a clamp jaw assembly.