Flexible Jaw Circuit Electrodes for RF Tissue Sensing Control
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Solution Overview
Problem
Traditional surgical instruments with rigid jaw electrodes face issues such as premature failure due to unwanted flexing, large surface area contact with tissue leading to sticking, and limited space for sensing devices.
Innovation Solution
A surgical instrument equipped with a flexible circuit comprising multiple sensors, including at least one therapeutic electrode and two sensing electrodes, with an insulative layer between the therapeutic and sensing electrodes, allowing for controlled RF energy delivery based on sensed signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If rigid jaw electrodes are used, then structural strength is improved, but premature failure occurs due to unwanted flexing
Solution Approach 1:
The patent replaces rigid jaw electrodes with flexible circuit electrodes that can accommodate the flexing and movement of the surgical instrument jaws without failing. The flexible circuit board with conductive traces maintains electrical connectivity while bending, eliminating the premature failure issue of rigid electrodes.
2Power
If large surface area electrodes are used, then therapeutic effect is improved, but tissue sticking increases
Solution Approach 1:
The patent divides the electrode surface into multiple smaller conductive traces on the flexible circuit board rather than using a single large continuous electrode. This segmentation reduces the total contact area with tissue while maintaining therapeutic effectiveness through distributed electrical delivery along the instrument shaft.
Solution Approach 2:
The patent extends the electrode surface area from a two-dimensional jaw face to a three-dimensional distribution along the length of the instrument shaft. The flexible circuit board carries multiple conductive traces that wrap around or extend along the shaft, providing therapeutic effect over a larger volume without increasing jaw contact area.
3Ease of manufacture
If rigid jaw electrodes are used, then manufacturing simplicity is improved, but limited space remains for sensing devices
Solution Approach 1:
The flexible circuit board serves multiple functions simultaneously: it provides structural support for the jaw, delivers therapeutic RF energy through conductive traces, and enables sensing through additional traces configured as sensors. This multi-functionality eliminates the need for separate rigid electrodes and sensing components, freeing up space while maintaining manufacturing efficiency.
Solution Approach 2:
The patent merges the electrode function and sensing function into a single flexible circuit board structure. The same flexible substrate that carries therapeutic conductive traces also carries sensing traces, combining multiple functions into one component and maximizing space utilization within the instrument.
4Measurement precision
If flexible circuit with multiple sensors is used, then sensing capability is improved, but device complexity increases
Solution Approach 1:
The patent uses uniform flexible circuit board construction with conductive traces for both therapeutic and sensing functions. The same manufacturing processes, materials, and design rules apply to all traces regardless of function, maintaining manufacturing simplicity while enabling multiple sensing capabilities. The homogeneous approach avoids introducing different component types that would increase complexity.
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 design enhances the performance of RF devices by reducing electrode failure, minimizing tissue sticking, and allowing for effective sensing and control of RF energy delivery.
Implementation Method 1
INTERRUPTION OF ENERGY DUE TO INADVERTENT CAPACITIVE COUPLING
Implementation Method 2
RADIO FREQUENCY ENERGY DEVICE FOR DELIVERING COMBINED ELECTRICAL SIGNALS
Data Source
AI summary
A method implemented by a surgical instrument is disclosed. The surgical instrument includes first and second jaws and a flexible circuit including multiple sensors to optimize performance of a radio frequency (RF) device. The flexible circuit includes at least one therapeutic electrode couplable to a source of RF energy, at least two sensing electrodes, and at least one insulative layer. The insulative layer is positioned between the at least one therapeutic electrode and the at least two sensing electrodes. The method includes contacting tissue positioned between the first and second jaws of the surgical instrument with the at least one therapeutic electrode and at the least two sensing electrodes; sensing signals from the at least two sensing electrodes; and controlling RF energy delivered to the at least one therapeutic electrode based on the sensed signals.