Plated Emitter Electrode Assembly for Flexible Ablation
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Solution Overview
Problem
Conventional electrode assemblies, particularly those with irrigation capabilities, are unable to flex sufficiently to access anatomical locations with greater degrees of curvature and sharper radii, limiting their effectiveness in treating intraosseous pathologies like bone tumors, and are often costly and prone to component failure.
Innovation Solution
A flexible electrode assembly with a unitary elongate body formed from a polymeric material like PEEK, featuring a bipolar design with distal and proximal emitters electrically insulated by a polymeric spacer, and including lumens for fluid infusion and a thermocouple, allowing for greater curvature and reduced manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If conventional electrode assemblies with irrigation capabilities are used, then fluid infusion function is provided, but flexibility to access anatomical locations with greater curvature is compromised
Solution Approach 1:
The patent merges the emitter, insulative spacer, and fluid infusion lumen into a single integrated elongate body structure. The emitters are formed by plating conductive material directly onto the polymeric elongate body, eliminating separate emitter components. The lumen is incorporated into the elongate body itself, removing the need for separate tubing or channels. This integration resolves the contradiction by providing fluid infusion capability without adding construction complexity, while maintaining flexibility.
Solution Approach 2:
The elongate body is constructed from a polymeric material that provides inherent flexibility, allowing the electrode assembly to navigate anatomical locations with greater curvature and sharper radii. This flexible polymeric construction replaces rigid metallic structures with irrigation capabilities, enabling the device to bend and conform to complex anatomical pathways while maintaining structural integrity and fluid delivery function.
2Adaptability or versatility
If conventional electrode assemblies with irrigation capabilities are used, then fluid infusion function is provided, but manufacturing cost increases
Solution Approach 1:
The patent combines multiple functions (emitter, insulator, fluid channel) into a single polymeric elongate body structure that can be manufactured as one piece. This integration eliminates the need for assembling multiple separate components, reducing manufacturing steps, assembly time, and potential failure points. The plating process directly applies conductive material to the polymeric body, creating emitters without requiring separate emitter manufacturing and attachment, thereby reducing overall manufacturing cost while maintaining fluid infusion capability.
3Reliability
If conventional electrode assemblies are used, then bipolar construction is achieved, but flexibility and access to difficult anatomical locations are limited
Solution Approach 1:
The polymeric elongate body provides inherent flexibility that allows the bipolar electrode assembly to navigate anatomical locations with greater curvature and sharper radii. The flexible construction enables the device to follow curved introducer assemblies and reach difficult-to-access sites such as posterior vertebral body locations, while the bipolar emitters remain properly positioned and electrically insulated throughout the flexing motion.
Solution Approach 2:
The integration of emitters directly onto the flexible polymeric elongate body ensures that the bipolar construction remains intact during flexing and bending. The insulative spacer is formed as part of the elongate body structure, maintaining electrical insulation between emitters even when the assembly is curved. This integrated design prevents component separation or misalignment that could occur with assembled bipolar constructs, ensuring reliable operation in challenging anatomical locations.
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 electrode assembly enables access to anatomically challenging locations with improved flexibility and reduced manufacturing costs, maintaining functionality even at greater bend angles and sharper curvatures, while preventing fluid egress that could compromise operation.
Implementation Method 1
an electrode assembly of the ablation system directs energy to the tissue to heat and destroy the cells of the tissue
Implementation Method 2
A thermocouple may be arranged to measure a temperature near the distal end of the electrode assembly
Data Source
AI summary
An electrode assembly including an elongate body, a proximal emitter, and a distal emitter. A discharge port may be in fluid communication with a lumen of the elongate body. The proximal and distal emitters are formed by plating a metal an outer surface of the elongate body that is polymeric. A portion of the elongate body forms an insulative spacer between the proximal and distal emitters. A distal cap may be coupled to the elongate body, formed from conductive material, and arranged in electrical communication with the distal emitter. A distal lead, a thermocouple, and/or a hypotube may be disposed within the lumen to form an electrical pathway with the distal cap. A sheath may be disposed over a portion of the proximal emitter, and a radiopaque marker may be coupled to the proximal emitter. Methods of fabricating the electrode assembly are also disclosed.