Disposable Bipolar Forceps with Thin Biocompatible Metal Coating
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Solution Overview
Problem
Existing bipolar electrosurgical forceps face issues with tissue sticking to the tips, leading to increased manufacturing costs due to the use of expensive biocompatible metals, and potential foreign material left in the body during sterilization processes.
Innovation Solution
Disposable forceps with thin layers of biocompatible metal, preferably silver or gold, applied to the distal ends of aluminum pincers, which are laser-cut and integrated with crimped electrical conductors, reducing material usage and manufacturing costs while ensuring biocompatibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If thick layers of expensive biocompatible metal (stainless steel, titanium, tungsten, gold, or silver) are used on forceps tips, then the forceps can be reused multiple times, but the manufacturing cost increases significantly
Solution Approach 1:
The patent applies the disposable principle by constructing forceps with a base material (such as stainless steel) that has a thin coating of biocompatible metal (less than 0.002 inches thick). This allows the forceps to be discarded after a single use, eliminating the need for expensive thick biocompatible metal layers while ensuring patient safety. The disposable nature resolves the contradiction by making the forceps inexpensive enough to manufacture as single-use items.
Solution Approach 2:
The patent uses composite materials by combining a base material (providing structural strength) with a thin layer of biocompatible metal coating (providing tissue compatibility). This composite structure allows the forceps to have sufficient durability for single use while keeping the biocompatible metal layer thin enough to be cost-effective, thus resolving the contradiction between reusability and manufacturing cost.
2Object-generated harmful factors
If forceps are sterilized by scrubbing or scraping after use, then tissue residue is removed, but portions of the biocompatible metal are removed from the tips
Solution Approach 1:
By making the forceps disposable, the patent eliminates the need for repeated sterilization processes that cause metal removal. The forceps are used once and then discarded, preventing the gradual loss of biocompatible metal that would occur with multiple scrubbing and sterilization cycles, thus resolving the contradiction between cleaning effectiveness and metal integrity.
3Reliability
If high temperature steam cleaning is used to sterilize forceps, then sterilization is effective, but the bond strength between biocompatible metal layers and forceps tips is reduced
Solution Approach 1:
The disposable design eliminates exposure to high-temperature steam sterilization that would weaken the metal bond. Since the forceps are discarded after one use, they never undergo the repeated thermal cycling that degrades the bonding between biocompatible metal layers and the base material, resolving the contradiction between sterilization effectiveness and bond strength.
4Object-generated harmful factors
If chemical cleaning is used on forceps, then tissue residue is removed, but the chemical composition of the tip metal layers changes (tarnishing or oxidation)
Solution Approach 1:
The disposable nature of the forceps prevents exposure to chemical cleaning agents that would cause tarnishing or oxidation of the biocompatible metal layers. By using the forceps once and discarding them, the metal composition remains stable and unchanged, resolving the contradiction between cleaning effectiveness and chemical stability.
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 enables the forceps to be used once and disposed of, reducing the risk of foreign material retention and lowering costs, while maintaining effective tissue coagulation and minimizing the need for extensive sterilization processes.
Implementation Method 1
the portions of the forceps tips that contact the body tissue be constructed or formed of a biocompatible material that will not react with the body tissue
Implementation Method 2
an electric current is completed from one forceps arm through the body tissue to the other forceps arm. This current passing through the forceps tips and the body tissue heats the forceps tips and the body tissue held between the tips and causes the tissue to be joined or coagulated
Implementation Method 3
thin layers of biocompatible metal on the forceps arm distal ends
Data Source
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AI summary
Disposable, bipolar electrosurgical forceps are designed to prevent the sticking of body tissue to the tips of the forceps and include a pair of electrode arms having lengths with opposite proximal and distal ends, with thin layers of biocompatible metal on the forceps arm distal ends and bipolar electrical conductors permanently secured to the forceps arm proximal ends.