Surgical End Effector Coating Patterning for Anti-Stick Sealing

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing surgical instruments face issues with tissue sticking and low burst pressure due to the addition of coating layers on tissue-contacting surfaces, which compromises surgical efficiency.

Innovation Solution

The application of a hydrophobic coating on tissue-contacting surfaces, followed by selectively removing portions of the coating using plasma or conductive ionic solution methods, to enhance anti-sticking performance and improve burst pressure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a coating layer is added to tissue-contacting surfaces, then anti-sticking performance is improved, but burst pressure decreases

Engineering Contradiction:

Improvetissue stickingVSAvoidburst pressure

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The coating is applied with localized removal to create specific patterns (e.g., circles, stripes, or random patterns) where the coating is present in some areas and removed in others. This allows the coating to provide anti-sticking properties in certain locations while maintaining burst pressure by removing coating in other locations, thus resolving the contradiction between anti-sticking performance and structural strength.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The coating layer is segmented into multiple regions with different coating densities or complete removal zones. By dividing the continuous coating into discrete patterns, the design achieves both anti-sticking functionality (where coating remains) and structural integrity (where coating is removed), eliminating the trade-off between these two properties.

Inventive Principle:

Principle #1Segmentation

2Object-affected harmful factors

If a coating layer is added to tissue-contacting surfaces, then anti-sticking performance is improved, but surgical efficiency decreases

Engineering Contradiction:

Improvetissue stickingVSAvoidsurgical efficiency

Core Design Contradiction:

Object-affected harmful factorsVSProductivity

Solution Approach 1:

By applying coating only in specific local areas rather than uniformly across the entire surface, the design reduces the total coating material required and maintains better thermal and electrical contact in critical areas, thereby improving surgical efficiency while still providing anti-sticking protection where needed.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The coating is selectively extracted or removed from certain regions to optimize performance. By taking out the coating from areas where it would interfere with surgical function (such as thermal delivery or electrical contact), the design improves surgical efficiency while retaining anti-sticking properties in areas where tissue contact occurs.

Inventive Principle:

Principle #2Taking out (Extraction)

3Object-affected harmful factors

If coating is uniformly applied, then anti-sticking performance is maximized, but burst pressure and surgical efficiency are compromised

Engineering Contradiction:

Improvetissue stickingVSAvoidburst pressure

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

Instead of applying coating uniformly across the entire surface, the design inverts the approach by removing coating from specific areas while leaving it in others. This inversion strategy allows the surface to achieve both anti-sticking properties (where coating remains) and structural strength (where coating is removed), resolving the contradiction between uniform coating benefits and localized performance requirements.

Inventive Principle:

Principle #13The other way round (Inversion)

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 method effectively reduces tissue sticking and enhances burst pressure, ensuring improved surgical efficiency and seal integrity.

Implementation Method 1

removing portions of the applied coating layer with a plasma removal method

Methodology Applied

Scientific EffectPlasma: Plasma

Implementation Method 2

removing portions of the applied coating layer with a conductive ionic solution method

Methodology Applied

Scientific EffectConduction (electrical): Conduction (electrical)

Data Source

PatentUS20260026867A1End effector and method of argon etching coating for applying electrical energy

Publication Date: 2026.01.29 CILAG GMBH INTERNATIONAL

AI summary

A method of manufacturing a surgical instrument that includes a tissue contacting surface operable to apply ultrasonic energy or RF energy to tissue. The method includes applying a hydrophobic coating that includes silicone to a base surface of the tissue contacting surface to form an applied coating layer having a coating application thickness. The method also includes removing portions of the applied coating layer with a plasma etching method to form a plurality of removed portions of coating. A removal depth of each removed portion of the plurality of removed portions can each be from 50% to 100% of the coating application thickness such that from 10% to 50% of the applied coating layer is removed from the base surface.