Heat-Shrinkable Insulation for Electrosurgical Generator Hub

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Solution Overview

Problem

Existing medical probes with RF electrodes face challenges in ensuring continuous electrical insulation at the hub-to-shaft interface, leading to potential tissue burns and inefficiencies in energy application due to gaps in insulation, which complicates the insertion and operation of probes during procedures.

Innovation Solution

The solution involves using heat-shrinkable electrically-insulative tubing to create a continuous, unbroken coating over the shaft and hub junction, ensuring no gaps and preventing electrical current leakage, thereby maintaining tissue safety and probe efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional insulation methods are used at the hub-to-shaft interface, then the probe structure is simpler, but gaps in insulation occur leading to tissue burns and current leakage

Engineering Contradiction:

Improveelectrical insulation continuityVSAvoidtissue burns and current leakage

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent applies heat-shrinkable electrically-insulative tubing as a flexible thin film structure that conformally coats the hub-to-shaft interface. This tubing shrinks to form a continuous insulating layer that eliminates gaps and prevents current leakage, directly resolving the tissue burn hazard while maintaining structural simplicity

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The patent utilizes the thermal parameter change of the heat-shrinkable tubing by applying heat to transform the tubing from an expanded state to a shrunk state. This parameter change enables the tubing to conformally adhere to the hub-to-shaft interface, creating continuous electrical insulation that prevents current leakage and tissue burns

Inventive Principle:

Principle #35Parameter changes

2Object-affected harmful factors

If heat-shrinkable tubing is applied to ensure continuous insulation, then tissue safety is improved, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvetissue burns preventionVSAvoidinsulation application process

Core Design Contradiction:

Object-affected harmful factorsVSEase of manufacture

Solution Approach 1:

The patent implements preliminary action by pre-attaching the heat-shrinkable tubing to the shaft assembly before final hub assembly. This preliminary insulation application ensures that the insulating layer is already in place and properly positioned, simplifying the overall manufacturing process while guaranteeing continuous electrical insulation at the critical hub-to-shaft interface

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent replaces complex mechanical insulation attachment methods with a thermal field-based solution. Instead of using adhesives, clips, or mechanical fasteners to secure insulation, the patent uses heat-shrinkable tubing that self-secures through thermal contraction, eliminating the need for additional mechanical attachment components and simplifying the manufacturing process

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

3Ease of manufacture

If gaps in insulation are present at the hub-to-shaft interface, then the probe is easier to manufacture, but RF energy application becomes inefficient and unsafe

Engineering Contradiction:

Improveinsulation assembly simplicityVSAvoidRF energy application efficiency

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent employs heat-shrinkable tubing as a flexible thin film that conformally covers the hub-to-shaft interface, creating a continuous insulating barrier that prevents RF energy leakage. This continuous insulation ensures that RF energy is directed only to the intended target tissue, improving treatment efficiency while the tubing's flexibility allows for simple assembly processes

Inventive Principle:

Principle #30Flexible shells and thin films

Solution Approach 2:

The heat-shrinkable tubing acts as an intermediary element between the metal shaft and the external environment, providing electrical isolation. This intermediary insulating layer prevents unwanted current paths and ensures that RF energy is efficiently delivered only to the intended target, while the tubing itself is easily applied through heat shrinking

Inventive Principle:

Principle #24Intermediary (Mediator)

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

This approach ensures complete electrical insulation, preventing tissue burns and enhancing the precision and reliability of RF energy application during medical procedures by maintaining a continuous, unbroken coating over the shaft and hub interface.

Implementation Method 1

heat-shrinkable electrically-insulative tubing

Methodology Applied

Scientific EffectHeat shrinkage: Thermal Contraction

Implementation Method 2

heating of the target tissue by RF power dissipation of the RF signal output in the target tissue

Methodology Applied

Scientific EffectRF power dissipation: Joule Heating

Data Source

PatentUS10194971B2Electrosurgical generator

Publication Date: 2019.02.05 BOSTON SCI NEUROMODULATION CORP

AI summary

A system and method for applying energy, particularly high-frequency (HF) energy, such as radiofrequency (RF) electrical energy, to a living body can include a cannula hub.