Thermally Controlled Surgical Illumination Waveguides With Bore Extraction
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Solution Overview
Problem
Existing illuminated surgical instruments face issues with thermal damage due to high energy density, which can cause burns, melt surgical drapes, and obstruct light output, while increasing the device profile to manage heat can obstruct the surgical field.
Innovation Solution
The use of optical waveguides with a large light extraction area, controlled energy density, and low profile design, featuring tapered or conical tapers and surface features like lenslets and prisms to distribute light uniformly across a larger surface area, minimizing thermal damage and maintaining visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If high intensity light energy is coupled into the illumination device, then illumination intensity on the surgical field is improved, but thermal damage risk increases
Solution Approach 1:
The patent transitions from point-source or small-area illumination to a large surface area illumination approach. By coupling the light source to an extended surface (such as a curved or planar light-guiding surface), the illumination is distributed across a broad area rather than concentrated at a single point, thereby reducing energy density and thermal risk while maintaining overall illumination intensity.
Solution Approach 2:
The patent changes the physical parameters of the illumination system by using materials with specific refractive indices and designing surfaces with controlled geometry (curved or planar). These parameter changes enable efficient light coupling and distribution across the surface area, transforming the illumination pattern from concentrated to distributed, thus resolving the thermal damage issue.
2Object-affected harmful factors
If the light extraction area is increased to reduce energy density, then thermal damage is reduced, but the device profile increases
Solution Approach 1:
The patent utilizes a two-dimensional or three-dimensional surface structure (curved or planar light-guiding surface) to provide a large light extraction area within a compact form factor. By configuring the light-guiding surface with appropriate curvature or geometry, the device achieves extended surface area without proportionally increasing the overall device length or profile.
Solution Approach 2:
The light-guiding surface is integrated within the existing device structure, nesting the illumination function within the device's body. This allows the light extraction area to be distributed along the device's surface without adding external bulk, thereby maintaining a compact profile while providing sufficient surface area for heat dissipation.
3Object-affected harmful factors
If a curved light-guiding surface is used to distribute light, then energy density is reduced, but manufacturing complexity increases
Solution Approach 1:
The patent specifies particular ranges for the radius of curvature and surface geometry parameters that balance optical performance with manufacturability. By defining concrete parameter ranges (e.g., radius of curvature between certain values), the design achieves the desired light distribution while remaining compatible with standard manufacturing processes such as molding or machining.
Solution Approach 2:
The patent employs a curved light-guiding surface with a defined radius of curvature to distribute light evenly across the illumination area. The curvature is optimized to achieve uniform energy distribution while being manufacturable using conventional techniques, avoiding excessively complex geometries that would be difficult or costly to produce.
4Illumination intensity
If modern light sources with high energy output are used, then illumination quality is improved, but thermal buildup on obstructed surfaces increases
Solution Approach 1:
The patent distributes the high energy output from modern light sources across a large two-dimensional or three-dimensional surface area. By coupling the light source to an extended light-guiding surface, the energy is spread out rather than concentrated, allowing high illumination quality to be achieved without excessive thermal buildup on any single point, including obstructed surfaces.
Solution Approach 2:
The patent acknowledges that high energy light sources produce thermal effects, but converts this potential harm into a benefit by using the thermal properties of the light-guiding surface material and geometry to distribute and dissipate heat evenly. The large surface area acts as a heat sink, and the curved or planar configuration promotes uniform thermal distribution, preventing localized overheating.
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 reduces thermal damage to instruments and patients, prevents surgical drape melting, and maintains clear visualization of the surgical field without increasing the device's profile.
Implementation Method 1
The light transmitting section transmits light from the light input section to the light output section
Implementation Method 2
the light extraction area is large enough to maintain the energy density of the light at a level that prevents melting or other damage of the illumination element or burning of the patient
Data Source
AI summary
An illumination element has a light input section, a light transmitting section, and a light output section. The light input section is optically coupled to a proximal section of the light transmitting section and inputs light into the illumination element. The light transmitting section transmits the light by total internal reflection or by other transmission means. The light output section is adjacent a distal section of the light transmitting section which has a light extraction area from which the light exits with an energy density. The light extraction area comprises a bore extending at least partially inward into a distal end of the light output section. A plurality of optical structures is disposed on an inner wall of the bore. The optical structures are configured to extract light from the light output section and direct it toward the surgical field.