Insulating coating for surgical blades and method of making same

Abstract

This invention provides an insulating coating for surgical blades, relating to the field of coating preparation technology. The coating, by weight, comprises the following components: 0.1-3 parts boron oxide; 0.1-1 parts zinc oxide; 2-6 parts silicon dioxide; 0.1-1 parts aluminum oxide; 0.1-1 parts calcium oxide; 0.1-1 parts magnesium oxide; 0.1-0.5 parts titanium dioxide; 0.1-0.5 parts iron oxide; 2-5 parts potassium oxide; 0.1-3 parts sodium oxide; 1-10 parts cobalt black; and 20-60 parts water. The coating of this invention possesses advantages such as good anti-adhesion, high lubricity, high hardness, and high-temperature resistance. The preparation method of this invention is simple, the materials are readily available, and the process is green and environmentally friendly.

Description

Technical Field

[0001] This invention relates to the field of coating materials technology, and in particular to an insulating coating for surgical blades and its preparation method. Background Technology

[0002] Electrosurgical scalpels are devices that use high-frequency electrical energy to cut, separate, and stop bleeding in surgical procedures. These include high-frequency electrosurgical units and plasma scalpels, and are essential medical instruments in various surgical procedures. When a conventional electrosurgical scalpel cuts, the high temperature causes tissue cells to dehydrate and denature. During surgery, this denatured tissue forms a crust that adheres to the scalpel tip. This crust is further carbonized by the high temperature of the electrosurgical unit, making the adhesion even stronger. The presence of this crust increases the resistance of the scalpel blade, leading to increased scalpel temperature. This not only affects cutting precision but also increases the risk of thermal damage to non-target tissues. Furthermore, the crust adhering to the blade surface is difficult to remove, requiring repeated manual cleaning and unnecessarily prolonging the surgeon's surgical time. Summary of the Invention

[0003] In view of the problems existing in the prior art, the present invention aims to provide an insulating coating with advantages such as good anti-adhesion, high lubricity, high hardness, and high temperature resistance.

[0004] Another objective of this invention is to provide a method for preparing an insulating coating for a scalpel tip. The scalpel tip prepared using the insulating coating and preparation method provided by this invention can achieve the technical effects of being quick and easy to cut tissue, not easily sticking, wear-resistant, and having a long service life.

[0005] To achieve the above objectives, the present invention provides the following technical solution:

[0006] An insulating coating for a surgical blade tip comprises, by weight, the following components: 0.1-3 parts boron oxide; 0.1-1 parts zinc oxide; 2-6 parts silicon dioxide; 0.1-1 parts aluminum oxide; 0.1-1 parts calcium oxide; 0.1-1 parts magnesium oxide; 0.1-0.5 parts titanium dioxide; 0.1-0.5 parts iron oxide; 2-5 parts potassium oxide; 0.1-3 parts sodium oxide; 1-10 parts cobalt black; and 20-60 parts water.

[0007] Preferably, it is composed of the following components: 1 part boron oxide, 1 part zinc oxide, 2 parts silicon dioxide, 1 part aluminum oxide, 1 part calcium oxide, 1 part magnesium oxide, 0.5 parts titanium dioxide, 0.5 parts iron oxide, 2 parts potassium oxide, 2 parts sodium oxide, 10 parts cobalt black, and 50 parts water.

[0008] Furthermore, the present invention provides a method for preparing an insulating coating for surgical blade tips, comprising:

[0009] Step S1: Weigh out boron oxide, zinc oxide, silicon dioxide, aluminum oxide, calcium oxide, magnesium oxide, titanium dioxide, iron oxide, potassium oxide and sodium oxide according to the weight parts, mix them evenly to obtain mixture A;

[0010] Step S2: Transfer mixture A to a furnace and obtain a melt at a melting temperature of 1000-2000℃;

[0011] Step S3: Clarify, homogenize, and remove bubbles from the melt. Specifically, during high-temperature clarification, the melt is continuously stirred to eliminate bubbles and streaks, while simultaneously making the material composition more uniform. The melting of a glassy molten material is a very complex process, involving a series of physical, chemical, and physicochemical phenomena and reactions. These phenomena and reactions result in the transformation of a mechanical mixture of various raw materials into a complex glassy molten material. During this process, many defects such as bubbles, inclusions, and streaks may occur, requiring clarification and homogenization to remove bubbles.

[0012] When mixture A is continuously heated, it begins to melt. The easily fusible eutectic mixture begins to melt first. During the melting process, the silicates and the remaining silica undergo intermelting. At the end of this stage, it becomes a glass melt at 1000-2000℃, but at this time, there are still a large number of bubbles and streaks in the melt.

[0013] High-temperature clarification involves further heating the molten glass, which reduces its viscosity and releases gaseous impurities, effectively removing visible bubbles. The clarification temperature is between 1400 and 1500°C.

[0014] Step S4: The molten material obtained in step S3 is crushed by water quenching. The specific steps are as follows: A discharge tank is set at the outlet of the furnace. Cooling water is drawn from the circulating water pipe into the discharge tank by a circulating water pump, so that the molten material entering the discharge tank is cooled and crushed into particles to obtain glass slag.

[0015] Step S5: Weigh the glass slag obtained in step S4, cobalt black, and water in a certain weight ratio and mix them evenly to obtain mixture B;

[0016] Step S6: Ball mill the mixture B in a ball mill jar, and after ball milling, pass it through a 200-mesh sieve to remove excess water, thereby obtaining an insulating coating for surgical scalpels;

[0017] Step S7: Apply insulating coating to the scalpel and place the coated scalpel tip at a high temperature to bake and react. As the reaction interface continues to decrease, the microscopic glass shards gradually melt, forming a continuous coating on the surface of the scalpel tip.

[0018] The preparation process of this invention involves separating the raw materials into two steps: mixture A and mixture B. This is mainly to first form a glassy object and to make the colorant more evenly distributed in the glass.

[0019] Preferably, in step S5, the amount of glass slag is 20-60 parts. Obviously, the other materials used are 10 parts cobalt black and 20-60 parts water.

[0020] Preferably, in step S6, both the grinding jar and the grinding balls are made of alumina; the grinding time is 48-96 hours.

[0021] Preferably, in step S7, the thickness of the insulating coating on the scalpel tip is 20-40 micrometers, the high-temperature baking temperature of the coated scalpel tip is 1000-1080℃, and the baking time is 1-5 minutes.

[0022] The beneficial effects of the technical solutions provided in the embodiments of the present invention include at least the following:

[0023] The baking temperature of this invention reaches 1000-1080℃, allowing low-melting-point impurities to volatilize and escape during the reaction, resulting in a high-purity coating. The addition of silica and titanium dioxide imparts lubricity, high hardness, and high-temperature resistance to the coating. Surgical blades prepared using the insulating coating and preparation method provided by this invention achieve rapid and easy cutting, are less prone to adhesion, are wear-resistant, and have a long service life, showing broad application prospects in electrosurgical scalpels. Detailed Implementation

[0024] In embodiments of the present invention, words such as "exemplarily," "for example," etc., are used to indicate that something is an example, illustration, or description. Any embodiment or design described as "exemplary" in the present invention should not be construed as being more preferred or advantageous than other embodiments or designs. Specifically, the use of the word "exemplary" is intended to present the concept in a concrete manner. Furthermore, in embodiments of the present invention, the meaning expressed by "and / or" can be both, or either one.

[0025] In this embodiment of the invention, the terms "image" and "picture" may sometimes be used interchangeably. It should be noted that, without emphasizing the difference, their intended meanings are consistent. Similarly, the terms "of," "corresponding," and "corresponding" may sometimes be used interchangeably. It should be noted that, without emphasizing the difference, their intended meanings are consistent.

[0026] In this embodiment of the invention, sometimes a subscript such as W1 may be mistakenly written as a non-subscript form such as W1. When the difference is not emphasized, the meaning they express is the same.

[0027] The following details the specific implementation methods.

[0028] Example 1:

[0029] An insulating coating for a surgical blade tip is composed of boron oxide, zinc oxide, silicon dioxide, aluminum oxide, calcium oxide, magnesium oxide, titanium dioxide, iron oxide, potassium oxide, sodium oxide, cobalt black, and water, with the weight components being 1, 1, 2, 1, 1, 1, 0.5, 0.5, 2, 2, 10, and 50 parts, respectively.

[0030] The method for preparing an insulating coating for surgical blade tips specifically includes the following steps:

[0031] S1: Mixture A is prepared by mixing raw materials in parts by weight: 1 part boron oxide, 1 part zinc oxide, 2 parts silicon dioxide, 1 part aluminum oxide, 1 part calcium oxide, 1 part magnesium oxide, 0.5 parts titanium dioxide, 0.5 parts iron oxide, 2 parts potassium oxide, and 2 parts sodium oxide.

[0032] S2: Mixture A is put into a melting furnace and melted at 1300-1600℃ to obtain a molten product;

[0033] S3: Clarify the melt at high temperature and stir to homogenize and remove air bubbles;

[0034] S4: The molten material obtained in S3 is sent into the discharge tank, and cooling water is introduced into the discharge tank. The clarified and homogenized molten material is crushed by water quenching to form glass slag.

[0035] S5: Mixture B is prepared by mixing raw materials in parts by weight: 30 parts glass slag, 10 parts cobalt black, and 50 parts water;

[0036] S6: Use an alumina ball mill jar and alumina grinding media balls to ball mill mixture B and pass it through a 200-mesh sieve for 48 hours;

[0037] S7: Apply an insulating coating to the scalpel tip; the coating thickness is 30 micrometers. Place the coated scalpel tip in a high-temperature baking environment (1000℃) for 2 minutes. After cooling, a scalpel tip with an insulating coating is obtained. The coated tip is smooth and easy to clean. When connected to a 60W high-frequency electrosurgical unit and intermittently stimulated in coagulation mode for 30 minutes, surface deposits are easily removed without coating peeling.

[0038] Comparative Example 1:

[0039] An insulating coating for a surgical blade tip is composed of boron oxide, zinc oxide, aluminum oxide, calcium oxide, magnesium oxide, iron oxide, potassium oxide, sodium oxide, cobalt black, and water, with the weight components being 1, 1, 1, 1, 1, 0.5, 2, 2, 10, and 50 parts, respectively.

[0040] The method for preparing an insulating coating for surgical blade tips specifically includes the following steps:

[0041] S1: Mixture A is prepared by mixing raw materials in parts by weight: 1 part boron oxide, 1 part zinc oxide, 1 part aluminum oxide, 1 part calcium oxide, 1 part magnesium oxide, 0.5 parts iron oxide, 2 parts potassium oxide, and 2 parts sodium oxide.

[0042] S2: Mixture A is put into a melting furnace and melted at 1300-1600℃ to obtain a molten product;

[0043] S3: Clarify the melt at high temperature and stir to homogenize and remove air bubbles;

[0044] S4: The molten material obtained in S3 is sent into the discharge tank, and cooling water is introduced into the discharge tank. The clarified and homogenized molten material is crushed by water quenching to form glass slag.

[0045] S5: Mixture B is prepared by mixing raw materials in parts by weight: 30 parts glass slag, 10 parts cobalt black, and 50 parts water;

[0046] S6: Use an alumina ball mill jar and alumina grinding media balls to ball mill mixture B and pass it through a 200-mesh sieve for 48 hours;

[0047] S7: Coat the scalpel tip with an insulating coating; the coating thickness is 30 micrometers; place the coated scalpel tip in a high-temperature baking environment at 1000℃ for 2 minutes. After cooling, a scalpel tip with an insulating coating is obtained.

[0048] Because no silica and titanium dioxide were added, the surface finish of the coated blade was poor, and adhesion occurred during continuous high-temperature operation: when connected to a high-frequency electrosurgical unit at 60W power and intermittently stimulated for 10 minutes in coagulation mode, obvious adhesion tissue appeared on the blade coating, forming carbonized eschar that was tightly bonded to the blade and difficult to remove.

[0049] Comparative Example 2:

[0050] An insulating coating for a surgical blade tip is composed of boron oxide, zinc oxide, silicon dioxide, aluminum oxide, calcium oxide, magnesium oxide, iron oxide, potassium oxide, sodium oxide, cobalt black, and water, with the weight components being 1, 1, 2, 1, 1, 1, 0.5, 2, 2, 10, and 50 parts, respectively.

[0051] The method for preparing an insulating coating for surgical blade tips specifically includes the following steps:

[0052] S1: Mixture A is prepared by mixing raw materials in parts by weight: 1 part boron oxide, 1 part zinc oxide, 2 parts silicon dioxide, 1 part aluminum oxide, 1 part calcium oxide, 1 part magnesium oxide, 0.5 parts iron oxide, 2 parts potassium oxide, and 2 parts sodium oxide.

[0053] S2: Mixture A is put into a melting furnace and melted at 1300-1600℃ to obtain a molten product;

[0054] S3: Clarify the melt at high temperature and stir to homogenize and remove air bubbles;

[0055] S4: The molten material obtained in S3 is sent into the discharge tank, and cooling water is introduced into the discharge tank. The clarified and homogenized molten material is crushed by water quenching to form glass slag.

[0056] S5: Mixture B is prepared by mixing raw materials in parts by weight: 30 parts glass slag, 10 parts cobalt black, and 50 parts water;

[0057] S6: Use an alumina ball mill jar and alumina grinding media balls to ball mill mixture B and pass it through a 200-mesh sieve for 48 hours;

[0058] S7: Coat the scalpel tip with an insulating coating; the coating thickness is 30 micrometers; place the coated scalpel tip in a high-temperature baking environment at 1000℃ for 2 minutes. After cooling, a scalpel tip with an insulating coating is obtained.

[0059] Because no titanium dioxide was added, although the surface of the coated tip was smooth, the coating peeled off during continuous high-temperature operation: when connected to a high-frequency electrosurgical unit at 60W power and intermittently stimulated for 20 minutes in coagulation mode, the coating turned white and some of the coating peeled off.

[0060] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A method for preparing an insulating coating, characterized in that, include: Step S1: Weigh out boron oxide, zinc oxide, silicon dioxide, aluminum oxide, calcium oxide, magnesium oxide, titanium dioxide, iron oxide, potassium oxide and sodium oxide according to the weight parts, mix them evenly to obtain mixture A; Step S2: Transfer mixture A to a furnace and obtain a melt at a melting temperature of 1000-2000℃; Step S3: Clarify, homogenize, and remove air bubbles from the melt at high temperature; Step S4: The molten material obtained in step S3 is crushed by water quenching to obtain glass slag; Step S5: Weigh the glass slag obtained in step S4, cobalt black, and water in a certain weight ratio and mix them evenly to obtain mixture B; Step S6: Ball mill the mixture B in a ball mill jar, and then pass it through a 200-mesh sieve to obtain the insulating coating for surgical knives; Step S7: Apply insulating coating to the scalpel and place the coated scalpel tip at a high temperature to bake and react, forming a continuous coating on the surface of the scalpel tip; In step S7, the coated surgical tip is baked at a high temperature of 1000-1080℃ for 1-5 minutes. The insulating coating is composed of the following components: 1 part boron oxide, 1 part zinc oxide, 2 parts silicon dioxide, 1 part aluminum oxide, 1 part calcium oxide, 1 part magnesium oxide, 0.5 parts titanium dioxide, 0.5 parts iron oxide, 2 parts potassium oxide, 2 parts sodium oxide, 10 parts cobalt black, and 50 parts water.

2. The method according to claim 1, characterized in that, In step S5, the amount of glass shards is 20-60 parts.

3. The method according to claim 1, characterized in that, In step S6, both the grinding jar and the grinding balls are made of alumina; the grinding time is 48-96 hours.

4. The method according to claim 1, characterized in that, In step S7, the thickness of the insulating coating on the scalpel tip is 20-40 micrometers.