Porous Metal Mesh Ablation Tips to Reduce Tissue Sticking
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Solution Overview
Problem
Existing ablative devices face issues with tissue sticking to biocompatible metal tips, leading to material loss and increased manufacturing costs due to the need for thicker metal layers to prolong device life, and sintered materials lack strength and durability for reusable devices.
Innovation Solution
The use of a biocompatible mesh material, which is fused and sintered, providing porosity for fluid conveyance and durability, allowing for disposable and reusable devices with reduced metal thickness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Duration of action of stationary object
If the thickness of biocompatible metal layer is increased to prolong device life, then the device can be used and sterilized more times before metal wears away, but the manufacturing cost significantly increases
Solution Approach 1:
The patent uses a composite structure combining biocompatible metal (such as titanium or stainless steel) with a porous coating layer made of biocompatible ceramic or polymer material. The metal substrate provides mechanical strength and durability, while the porous coating layer provides tissue-friendly surface properties and resistance to tissue adhesion. This composite approach allows the device to maintain adequate metal thickness for structural integrity without requiring excessive metal layer thickness, thus controlling manufacturing costs while extending device lifespan through the protective and non-stick properties of the coating layer.
2Reliability
If conventional biocompatible metal tips are used, then the device is biocompatible, but heat production causes body tissue to stick to the metal tips
Solution Approach 1:
The patent applies a porous coating layer on the biocompatible metal tips that allows conductive fluid to pass through. This porous structure prevents direct contact between the metal surface and body tissue, reducing heat transfer and tissue sticking. The pores enable coolant flow to reach the tissue interface, carrying away heat and preventing carbonization and adhesion of tissue to the tip surface, while the underlying biocompatible metal maintains its biocompatibility.
3Ease of manufacture
If the biocompatible metal layer is made thinner to reduce cost, then manufacturing cost decreases, but the device wears away more quickly requiring more frequent replacement
Solution Approach 1:
The patent implements local quality by applying a specialized porous coating layer only on the distal tips of the forceps where tissue contact occurs. This localized treatment provides enhanced wear resistance and non-stick properties exactly where needed, protecting the thinner metal substrate from direct tissue contact and mechanical wear. The coating layer acts as a sacrificial protective layer that can be replaced or regenerated, allowing the underlying metal structure to remain thin and cost-effective while the device maintains its functional lifespan through the protective coating.
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 mesh material reduces tissue sticking and manufacturing costs while maintaining durability, enabling efficient energy delivery and fluid conveyance for ablative procedures.
Implementation Method 1
subjecting the blend to high temperatures. When compacting the particles, a controlled amount of the mixed powder is automatically gravity-fed into a precision die and is compacted, usually at room temperature at low pressures. Once it is ejected from the die, and will be sufficiently rigid to permit in-process handling and transport to a sintering furnace. During sintering, the unfinished material is placed within a controlled-atmosphere furnace, and is heated to below the melting point of the base metal, held at the sintering temperature, and then cooled.
Implementation Method 2
heated to below the melting point of the base metal, held at the sintering temperature
Implementation Method 3
Conductive fluid has been shown to reduce the local temperature of the tissue being ablated, minimizing tissue vaporization and charring.
Implementation Method 4
the distal ends of the device, or the entirety of the forceps electrode arms or probe shaft are composed of a porous structure to allow for the conductive fluid to be conveyed through the lumen and out through the porous structure into adjacent tissue
Data Source
AI summary
The present disclosure is directed to ablative devices comprising biocompatible materials in the form of a mesh to provide porosity to allow for the conveyance of conductive fluid to target tissue to be ablated. The mesh also increases the durability of the biocompatible material, reducing the amount of biocompatible material needed for both reusable devices and disposable ablative devices, such as ablative forceps and ablative probes.