Porous CO2 Diffuser Tip for Stable Surgical Gas Cushioning

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Solution Overview

Problem

Existing gas insufflators fail to provide a stable, laminar flow of CO2 to create a protective gas cushion in surgical environments, leading to potential air emboli and infection risks due to turbulence and air mixing.

Innovation Solution

A device comprising a flexible hose and a distal tip with a rigid, porous polymer body having a pore size of 7 to 45 μm, which supplies gas in a substantially laminar, continuous flow to form a protective gas cushion, preventing environmental air from reaching the surgical site.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If gas is supplied through conventional insufflators, then gas flow is achieved, but turbulent flow is created which mixes environmental air with the local CO2 atmosphere

Engineering Contradiction:
Improvestability of local CO2 atmosphereVSAvoidturbulence mixing air with CO2 atmosphere
Core Design Contradiction:
ReliabilityVSObject-generated harmful factors

Solution Approach 1:

The patent employs a porous diffuser element with controlled pore sizes (10-100 micrometers) to transform the gas flow regime. The porous structure distributes gas through numerous small channels, creating a laminar flow pattern that prevents turbulence and maintains a stable local CO2 atmosphere without mixing with environmental air.

Inventive Principle:
Principle #31Porous materials

Solution Approach 2:

The patent changes the physical parameters of gas flow by controlling pore size (10-100 micrometers) and gas flow rate (0.5-5 liters per minute) to transition from turbulent to laminar flow. This parameter optimization ensures smooth gas delivery that maintains atmospheric stability while preventing air contamination.

Inventive Principle:
Principle #35Parameter changes

2Area of stationary object

If gas flow rate is increased to ensure adequate coverage, then gas cushion formation is improved, but turbulence increases and mixes environmental air with the CO2 atmosphere

Engineering Contradiction:
Improvecoverage area of gas cushionVSAvoidturbulence
Core Design Contradiction:
Area of stationary objectVSObject-generated harmful factors

Solution Approach 1:

The patent segments the gas flow into numerous small streams through the porous structure with multiple pores. This segmentation allows the total gas flow to be distributed across many micro-channels, maintaining laminar flow characteristics even at higher overall flow rates, thereby expanding coverage area without inducing turbulence.

Inventive Principle:
Principle #1Segmentation

Solution Approach 2:

The porous diffuser enables high flow rates to be delivered while maintaining laminar flow through its controlled pore architecture. The material structure ensures that increased gas volume is distributed smoothly across the surgical field without creating turbulent mixing with environmental air.

Inventive Principle:
Principle #31Porous materials

3Productivity

If conventional diffusers are used, then gas delivery is achieved, but air from the environment mixes with the local CO2 atmosphere increasing risk of air emboli and infections

Engineering Contradiction:
Improvegas delivery efficiencyVSAvoidair emboli and infections risk
Core Design Contradiction:
ProductivityVSObject-affected harmful factors

Solution Approach 1:

The patent creates and maintains an inert CO2 atmosphere by delivering gas through a laminar flow system that prevents mixing with environmental air. The controlled laminar flow ensures the CO2 cushion remains isolated from air-containing environments, eliminating the risk of air emboli and reducing infection risk while maintaining efficient gas delivery.

Inventive Principle:
Principle #39Inert atmosphere (Inert environment)

Solution Approach 2:

By optimizing gas flow parameters (laminar flow regime, controlled velocity, appropriate pore size), the patent achieves efficient gas delivery that maintains a pure CO2 atmosphere. The parameter control prevents air contamination while ensuring adequate gas supply to maintain the protective atmosphere.

Inventive Principle:
Principle #35Parameter changes

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 device ensures a stable CO2 atmosphere with minimal turbulence, reducing air emboli and infections by forming a protective gas cushion that maintains separation from surrounding air, using CO2's high solubility and bacteriostatic properties.

Implementation Method 1

the rigid, porous polymer body being arranged to supply the volume with the gas in a substantially laminar, continuous flow

Methodology Applied
Scientific EffectLaminar flow: Laminar Flow

Implementation Method 2

a rigid, porous polymer body having a pore size of 7 to 45 μm

Methodology Applied
Scientific EffectPorosity: Porosity

Data Source

PatentUS12629486B2Devices and methods to create a protective gas cushion
Publication Date: 2026.05.19 BLACKLOCK CHRISTOPHER STEPHEN
  • US12629486B2 patent drawing
  • US12629486B2 patent drawing
  • US12629486B2 patent drawing

AI summary

Devices and methods for creating a protective gas cushion in an outwardly open volume which are useful in surgery are provided. More particularly, the invention relates to a device having a flexible hose portion having an intake end and a discharge end and a distal tip portion connected to the discharge end of the flexible hose portion. The distal tip portion comprises a rigid, porous polymer body having a pore size of 7 to 45 μm. The distal tip portion is adapted to be positioned in the volume and the device is arranged to supply the gas to the volume through the rigid, porous polymer body, the rigid, porous polymer body being arranged to supply the volume with the gas in a substantially laminar, continuous flow to enable the formation of the protective gas cushion intended to fill the volume and prevent air from the environment from reaching the volume.