Stitched Insulative Filament Electrode Spacers for Electrosurgery

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Solution Overview

Problem

There is a need for improved electrically insulative spacers in electrosurgical instruments that are durable, facilitate manufacturing, and provide a large exposed area for electrode surfaces while preventing short circuits and arcing.

Innovation Solution

The use of filamentary electrically insulative materials, such as aramids or cotton, stitched into the electrodes to create a gap between opposing electrodes, with exposed segments that maintain the desired spacing and are coated for enhanced durability and resistance to body fluids.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional insulative spacers are used to maintain gap between electrodes, then short circuit prevention is achieved, but the exposed electrode area is reduced and manufacturing complexity increases

Engineering Contradiction:

Improveshort circuit preventionVSAvoidexposed electrode area

Core Design Contradiction:

ReliabilityVSArea of stationary object

Solution Approach 1:

The insulative spacer is segmented into discrete filament elements that are stitched at specific intervals across the electrode surface. This segmentation allows the spacers to be distributed in a pattern that prevents short circuits while minimizing the total area occupied by the insulative material, thereby maximizing the exposed electrode area for energy delivery.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent uses thin filamentary insulative materials that are stitched into the electrode structure. These thin film-like spacers provide effective electrical insulation and mechanical gap maintenance while occupying minimal space, thus preserving maximum exposed electrode surface area for therapeutic energy delivery.

Inventive Principle:

Principle #30Flexible shells and thin films

2Reliability

If insulative spacers are added to prevent arcing and maintain spacing, then electrode separation is ensured, but device complexity increases

Engineering Contradiction:

Improvearcing preventionVSAvoidspacer mechanism complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The insulative spacer filaments are merged with the electrode structure through stitching, where the spacers are integrated into the electrode assembly during manufacturing. This combination eliminates the need for separate spacer installation steps and simplifies the overall device structure while maintaining effective electrode separation and arcing prevention.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The spacer filaments are stitched directly into the electrode structure during the electrode manufacturing process itself. This self-service approach integrates the spacer function into the existing manufacturing workflow, eliminating the need for additional spacer installation steps and reducing overall device complexity.

Inventive Principle:

Principle #25Self-service

3Ease of manufacture

If standard insulative materials are used for spacers, then manufacturing is simplified, but durability under high temperature and body fluid exposure is reduced

Engineering Contradiction:

Improvespacer manufacturing easeVSAvoidspacer durability

Core Design Contradiction:

Ease of manufactureVSStrength

Solution Approach 1:

The patent employs composite material construction where insulative spacer filaments are coated with or impregnated by biocompatible polymers or resins. This composite approach combines the electrical insulative properties of the base filament material with the thermal and chemical resistance of the coating material, resulting in spacers that maintain durability under high temperature and body fluid exposure while remaining manufacturable through standard stitching processes.

Inventive Principle:

Principle #40Composite materials

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 solution effectively prevents short circuits and arcing, maintains electrode spacing, and enhances the durability of the spacers, ensuring reliable operation under high temperatures and during surgical procedures.

Implementation Method 1

an electrically insulative filament positioned on a working surface of the electrode and at least partially extending through the thickness of the electrode

Methodology Applied

Scientific EffectElectrical insulation: Electrical Resistance

Implementation Method 2

maintain a gap between opposing electrodes... prevent a short circuit by impeding (e.g., preventing) the electrode surfaces from being driven into mutual contact

Methodology Applied

Scientific EffectPhysical separation: Physical Containment

Data Source

PatentUS12256978B2Electrically insulative electrode spacers, and related devices, systems, and methods

Publication Date: 2025.03.25 INTUITIVE SURGICAL OPERATIONS INC

AI summary

A method for making an electrode assembly comprises overlaying an electrode on an electrode support, the electrode comprising a plurality of openings extending at least partially through a thickness of the electrode; supporting the electrode support with a jaw body; stitching a filament made of electrically insulative material comprising a first inset segment and exposed segment into a first opening of the plurality of openings such that the first inset segment is positioned in the first opening and at least a portion of the exposed segment is positioned to overlie an exposed working surface of the electrode; and affixing at least an end portion of the first inset segment of the filament to the electrode, electrode support, and/or the jaw body.