Electrosurgical Electrode Laser Roughening for Insulating Stop Bonding
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Solution Overview
Problem
Existing electrosurgical vessel sealing devices face challenges with adhesion quality, flexibility, and manufacturing costs due to conventional methods like chemical etching, bead/sand blasting, and stamped recesses for attaching insulating stops to electrodes, which are complex and inflexible.
Innovation Solution
A method involving laser etching to roughen the electrode surface for improved adhesion of insulating stops, allowing for spatial accuracy, non-contact processing, and integration into the manufacturing process without altering electrode integrity, and enabling efficient production with fewer tooling changes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If chemical etching or bead/sand blasting is used to roughen the electrode surface, then adhesion quality between electrode and insulating stop is improved, but manufacturing complexity and cost increase due to mask requirements and process inflexibility
Solution Approach 1:
The patent replaces mechanical/chemical processes (bead blasting, chemical etching with masks) with a laser-based process. The laser locally roughens the electrode surface through ablation without requiring masks or chemical agents, thereby improving adhesion quality while reducing manufacturing complexity and increasing design flexibility.
Solution Approach 2:
The patent changes the manufacturing parameter from chemical/mechanical processes to optical/thermal laser processing. By controlling laser parameters (power, speed, pattern), the surface roughness can be precisely controlled to optimize adhesion without the constraints of mask-based methods.
2Ease of manufacture
If stamped recesses are used to attach insulating stops, then manufacturing process is simplified, but adhesion quality and electrode integrity are compromised
Solution Approach 1:
The patent replaces the mechanical stamping process with laser surface treatment. Instead of creating recesses that compromise electrode integrity, the laser locally roughens the surface, providing excellent adhesion quality while maintaining electrode structural integrity and simplifying the manufacturing process.
3Strength
If conventional etching methods are used, then insulating stop attachment is improved, but flexibility to change design is reduced due to mask production requirements
Solution Approach 1:
The patent replaces mask-based chemical etching with direct laser writing. This allows design changes to be implemented by simply modifying the laser pattern software, providing complete design flexibility without the cost and time of producing new masks, while maintaining strong bond strength through controlled surface roughness.
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
This method enhances the bond between the electrode and insulating stops, reduces manufacturing complexity and costs, and ensures effective prevention of short circuits during electrosurgical procedures.
Implementation Method 1
a laser is used to locally etch or roughen the area of the electrode where the insulating stop is to be attached prior to the insulating stop being bonded thereto
Data Source
AI summary
An electrode for the electrosurgical end effector of a surgical instrument is manufactured by laser etching or roughening an area of the electrode's surface. This provides an area to which an insulating stop may be attached. Beneficially, the roughened area provides a good bond between the insulating stop and the electrode, allowing a greater potential use-life for the surgical instrument. Compared to conventional methods, using a laser reduces costs, increases manufacturing flexibility and allows precise control over the creation of the roughened area.