Ultrasonic Flue Protrusion Pattern for Thermal Management
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Solution Overview
Problem
Conventional ultrasonic surgical aspirators experience thermal rise issues due to vibration-induced heating, which can lead to tissue burns, especially during procedures like endonasal approaches where the tip and flue are angulated, and existing flues with sparse protrusions are inadequate in protecting tissue from high strain areas.
Innovation Solution
The design incorporates a flue with an enhanced protrusion pattern and density, including spherical protrusions distributed in staggered rows and columns, forming bridges that limit contact between the flue and ultrasonic horn, particularly at high strain and motion areas, to reduce thermal rise and prevent tissue burns.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional flues with sparse protrusions are used, then the device complexity is low, but the thermal rise protection is insufficient leading to tissue burns
Solution Approach 1:
The flue is equipped with protrusions at specific locations corresponding to high strain and motion areas of the ultrasonic horn. This localized protection approach concentrates the protective function where thermal rise is most severe, rather than uniformly distributing protrusions across the entire flue surface, thus addressing the harmful thermal effects without excessive overall complexity
Solution Approach 2:
The protrusions are positioned in advance at locations that correspond to high strain and motion areas of the ultrasonic horn, creating bridges before thermal contact occurs. This preliminary positioning prevents the flue from contacting the horn at critical hot spots during operation, proactively preventing tissue burns before they can occur
2Stability of the object's composition
If the flue contact area with the ultrasonic horn is increased, then structural stability improves, but thermal rise increases causing tissue burns
Solution Approach 1:
The flue surface is segmented with discrete protrusions rather than continuous contact. This segmentation creates multiple small contact points (bridges) that provide structural stability while minimizing the total contact area, thereby reducing heat transfer from the ultrasonic horn to the flue and preventing tissue burns
Solution Approach 2:
The flue acts as a flexible protective shell that conforms to the ultrasonic horn while maintaining minimal contact through protrusion bridges. This flexible design provides structural stability and positioning while limiting thermal conduction, as the thin flue material with reduced contact area does not efficiently conduct heat from the horn
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 improved flue design effectively reduces thermal rise under both nominal and excessive loading conditions, minimizing the risk of tissue burns and maintaining effective irrigation fluid flow, as demonstrated by cadaver lab and point load testing.
Implementation Method 1
A magnetostrictive transducer coupled with the connecting body functions as a first stage of the booster horn
Implementation Method 2
The Gaussian profile is used in practice to establish and control the resonance and mechanical gain of horns
Implementation Method 3
The plurality of protrusions form one or more bridges that limit contact between the arcuate region of the internal surface of the flue and the external surface of the ultrasonic horn, thereby reducing thermal rise
Data Source
AI summary
A flue for use with an ultrasonic surgical tip, comprising protrusions or bumps on its inner surface with improved protrusion pattern, density and location. The flue has enhanced cooling effect for the ultrasonic surgical tip.