Laser-Patterned End Effector Coating for Tissue Sticking Control
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Solution Overview
Problem
Surgical instruments with tissue-contacting surfaces experience tissue sticking due to coating layers that limit electrical field generation, leading to reduced work done on tissue and low burst pressure.
Innovation Solution
Applying a hydrophobic coating to the tissue-contacting surfaces and selectively removing portions of the coating using laser technology to improve electrical current transfer and reduce sticking.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If a coating layer is applied to the tissue-contacting surface, then tissue sticking is reduced, but electrical field generation is limited and work done on tissue is reduced
Solution Approach 1:
The patent applies local quality by creating a patterned coating where different regions have different properties: some areas have coating (for anti-sticking) while others are coating-free (for electrical field generation). This is achieved through selective removal processes that create a non-uniform surface treatment, allowing simultaneous optimization of both anti-sticking performance and electrical field generation in different locations on the same surface.
Solution Approach 2:
The coating layer is segmented into multiple regions with different functions. The patent divides the surface into coating-covered areas (providing anti-sticking properties) and coating-removed areas (providing electrical field generation). This segmentation allows the single surface to perform multiple functions simultaneously, resolving the contradiction between reducing tissue sticking and maintaining adequate work done on tissue.
2Object-affected harmful factors
If a coating layer is applied to the tissue-contacting surface, then tissue sticking is reduced, but electrical current transfer is limited
Solution Approach 1:
The patent creates local quality variations by selectively removing coating in specific patterns to expose underlying conductive surfaces. These coating-free zones serve as electrical current transfer pathways while the remaining coating areas maintain anti-sticking properties. This localized differentiation resolves the contradiction between preventing tissue adhesion and ensuring reliable electrical current transfer.
Solution Approach 2:
The patterned coating structure acts as an intermediary between the conflicting requirements of anti-sticking and electrical conduction. By creating a spatially varying coating distribution, the surface mediates between these two opposing needs, providing both protective non-stick properties and conductive pathways for electrical current transfer without requiring separate components.
3Power
If coating portions are removed to improve electrical field generation, then work done on tissue is improved, but anti-sticking performance may be compromised
Solution Approach 1:
The patent resolves this contradiction by applying local quality - different regions of the surface have different coating states optimized for different functions. Coating-removed regions provide enhanced electrical field generation and work done on tissue, while adjacent coating-retained regions maintain anti-sticking performance. This spatial differentiation allows both requirements to be satisfied simultaneously in different locations.
Solution Approach 2:
The surface functionality is segmented into distinct zones: one segment optimized for electrical field generation (coating removed) and another segment optimized for preventing tissue sticking (coating retained). This functional segmentation allows the patent to improve work done on tissue through selective coating removal while preserving anti-sticking performance in other areas, thereby resolving the contradiction between these two performance metrics.
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
Enhances electrical current transfer and burst performance while maintaining anti-sticking performance, improving surgical efficiency and tissue seal quality.
Implementation Method 1
selectively removing portions of the coating using laser technology
Implementation Method 2
Applying a hydrophobic coating to the tissue-contacting surfaces
Data Source
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 laser 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.