Flexible Sensor Circuit for RF Jaw Electrode Durability
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Solution Overview
Problem
Surgical instruments with rigid electrodes experience premature failure due to unwanted flexing and deformation, and traditional electrical circuits fail to maintain contact under varying forces, leading to inefficient radio-frequency energy delivery and tissue sticking issues.
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 them, allowing for controlled RF energy delivery based on sensed signals.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Stability of the object's composition
If rigid electrodes are used in surgical instruments, then structural stability is improved, but the electrodes experience premature failure due to unwanted flexing and deformation
Solution Approach 1:
The patent applies this principle by replacing rigid electrodes with flexible circuit boards that have a thin film structure. The flexible circuit board includes a substrate with conductive traces that can bend and deform without breaking, eliminating the premature failure experienced by rigid electrodes while maintaining electrical functionality.
Solution Approach 2:
The patent applies this principle by creating a composite structure where the flexible circuit board combines multiple materials: a flexible substrate (such as polyimide or polyester), conductive traces (such as copper or silver), and insulating layers. This composite construction provides both flexibility and electrical conductivity, resolving the contradiction between structural stability and durability.
2Device complexity
If traditional electrical circuits are used, then device simplicity is maintained, but contact is not maintained under varying forces leading to inefficient RF energy delivery
Solution Approach 1:
The flexible circuit board acts as a thin film that can conform to varying forces and maintain continuous electrical contact. The flexible substrate allows the circuit to bend and deform with the surgical instrument without breaking connections, ensuring reliable RF energy delivery while maintaining a relatively simple overall device structure.
Solution Approach 2:
The patent applies this principle by making the electrical circuit dynamic rather than static. The flexible circuit board can adapt its shape and position in response to varying forces during surgical procedures, maintaining optimal contact and electrical connection throughout the range of motion, thereby ensuring consistent RF energy delivery.
3Measurement precision
If multiple sensors are integrated into the flexible circuit, then RF energy delivery control precision is improved, but device complexity increases
Solution Approach 1:
The patent applies this principle by merging multiple sensors (such as force sensors, temperature sensors, and position sensors) directly into the flexible circuit board structure. This integration allows the sensors to work together in a unified system, providing precise control of RF energy delivery while avoiding the complexity of separate sensor assemblies and their associated wiring.
Solution Approach 2:
The flexible circuit board serves multiple functions simultaneously: it provides structural support, conducts electrical signals for RF energy delivery, and houses multiple sensors for monitoring various parameters. This multi-functionality reduces the need for separate components and simplifies the overall device architecture while maintaining precise control capabilities.
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 durability and efficiency of RF energy delivery, reducing tissue sticking and electrode failure, while allowing for precise control of energy application.
Implementation Method 1
INTERRUPTION OF ENERGY DUE TO INADVERTENT CAPACITIVE COUPLING
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.