PEO-Coated Thermal Cutting Element for Precise Tissue Severing
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Solution Overview
Problem
Existing surgical instruments face challenges in accurately severing treated tissue after energy-based tissue treatment, as they rely on mechanical knives which may not be precise or efficient.
Innovation Solution
A thermal cutting element is developed, featuring a Plasma Electrolytic Oxidation (PEO) coated substrate with a heating element that connects to different electrical potentials, allowing for precise thermal cutting of tissue, integrated into a surgical instrument's jaw member with a tissue-treating plate and attachment flange for secure placement.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a mechanical knife is used to cut treated tissue, then the instrument can sever tissue, but the cutting precision and efficiency are insufficient
Solution Approach 1:
The patent replaces the mechanical knife system with a thermal cutting element that uses electrical energy to heat and cut tissue. The heating element converts electrical energy to thermal energy, eliminating the need for mechanical blade movement and contact, thereby improving both cutting precision and efficiency through controlled thermal energy delivery.
Solution Approach 2:
The patent changes the cutting mechanism from mechanical force to thermal energy by controlling electrical parameters (voltage, current, power) delivered to the heating element. This parameter change enables precise control over cutting temperature and energy delivery, achieving superior cutting precision and efficiency compared to mechanical methods.
2Productivity
If a thermal cutting element is used, then cutting precision and efficiency are improved, but the device complexity increases due to additional coating and electrical components
Solution Approach 1:
The patent uses a composite structure consisting of a substrate with a Plasma Electrolytic Oxidation (PEO) coating layer and an integrated heating element. This composite design combines the mechanical strength of the substrate with the thermal and electrical properties of the coating and heating element, achieving high cutting efficiency while managing device complexity through integrated material functionality.
3Reliability
If a PEO coating is applied to the substrate, then the thermal cutting performance is enhanced, but the manufacturing process becomes more complex
Solution Approach 1:
The patent applies Plasma Electrolytic Oxidation (PEO) coating to the substrate, which is a surface treatment process that transforms the substrate surface properties through controlled electrochemical reactions. This parameter change in surface treatment enhances thermal cutting performance by improving heat distribution and tissue adhesion, while the PEO process itself is a established manufacturing technique that can be integrated into existing production lines.
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 thermal cutting element enables precise and efficient thermal cutting of treated tissue, improving the accuracy and reliability of tissue severing processes in surgical instruments by utilizing a PEO-coated substrate with a heating element that connects to different electrical potentials, ensuring effective energy delivery for cutting.
Implementation Method 1
a heating element disposed on the PEO coating and including first and second end portions adapted to connect to different potentials of electrical energy to heat the heating element
Implementation Method 2
a Plasma Electrolytic Oxidation (PEO) coating disposed on the substrate
Data Source
AI summary
A thermal cutting element for a surgical instrument includes a substrate, a Plasma Electrolytic Oxidation (PEO) coating disposed on the substrate, and a heating element disposed on the PEO coating and including first and second end portions adapted to connect to different potentials of electrical energy to heat the heating element. A jaw member of a surgical instrument includes a structural frame including a proximal flange portion and a distal body portion, a jaw housing surrounding the distal body portion of the structural frame, a tissue-treating plate disposed atop the jaw housing and defining a longitudinal slot therethrough along at least a portion of a length thereof, and the thermal cutting element disposed within the longitudinal slot.