Micro-patterned Surgical Instrument Surface for Tissue Adhesion
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Solution Overview
Problem
Existing ultrasonic and electrosurgical instruments face issues with tissue sticking due to heat generation during tissue sealing and cutting, leading to reduced surgical efficiency, as conventional hydrophobic coatings wear off quickly.
Innovation Solution
The implementation of microscopic surface patterns and nanoscopic surface roughness, combined with hydrophobic coatings, on the energized features of surgical instruments to reduce tissue sticking, with the patterns and roughness structures being formed using techniques like laser ablation and chemical etching, and the coatings applied through methods such as plasma treatment and dip coating.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional hydrophobic coatings are applied to the energized feature, then tissue sticking is reduced, but the coating wears off quickly during surgical use
Solution Approach 1:
The surface of the energized feature is segmented into multiple microscopic protrusions rather than being smooth. This segmentation creates a textured surface structure that mechanically reduces tissue contact area and prevents tissue adhesion, providing a durable solution that does not rely solely on coating integrity
Solution Approach 2:
The invention combines the hydrophobic coating with the micropatterned surface structure to create a composite surface treatment. The coating provides chemical hydrophobicity while the microscopic protrusions provide physical non-stick properties, and the coating adheres to the protrusion surfaces, creating a synergistic effect that maintains non-stick performance even as the coating wears
2Productivity
If the energized feature contacts tissue during ultrasonic or RF energy application, then tissue sealing and cutting are achieved, but heat generation causes tissue to stick to the surface
Solution Approach 1:
The energized feature has different surface properties at different scales: at the macro level, it provides continuous contact for effective energy transfer to tissue; at the micro level, the protrusions create localized non-stick zones that prevent adhesion. This local quality differentiation allows simultaneous achievement of sealing efficiency and anti-sticking performance
Solution Approach 2:
The heat generation that causes tissue sticking is converted into a benefit by using the micropatterned surface to manage thermal effects. The reduced contact area between tissue and energized feature minimizes heat transfer to the instrument surface, preventing tissue adhesion while maintaining effective tissue sealing through the contact that does occur
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
These surface modifications significantly reduce tissue sticking and enhance the durability of hydrophobic coatings, maintaining non-stick performance even after wear, thus improving surgical efficiency and instrument longevity.
Implementation Method 1
applying a hydrophobic coating to at least one of the recessed portions of the microscopic surface pattern or the valleys of the nanoscopic surface roughness
Implementation Method 2
forming at least one of a microscopic surface pattern or a nanoscopic surface roughness into a base surface of the energized feature
Implementation Method 3
the coatings applied through methods such as plasma treatment and dip coating
Data Source
AI summary
A method of manufacturing a surgical instrument that includes an energized feature operable to apply ultrasonic energy or RF energy to tissue. The method includes forming at least one of a microscopic surface pattern or a nanoscopic surface roughness into a base surface of the energized feature to produce at least one recessed portion. The method also includes applying a hydrophobic coating that includes at least one of silicone, titanium nitride, chromium nitride, or titanium aluminum nitride to at least the recessed portion of the energized feature after forming at least one of the microscopic surface pattern or the nanoscopic surface roughness.