RF Tag Attachment to Surgical Sponges Using UV-Cured Adhesive

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

In operation rooms, manually attaching RF tags to sponge items is time-consuming and costly, and existing methods fail to mechanize the process effectively due to varying sizes and models, leading to errors in tracking and potential tools left inside patients, which increases risks and costs.

Innovation Solution

A method and system using UV-curable adhesive material to attach RF tags to sponge items, where the adhesive is applied to the tag or the sponge, and cured with ultraviolet radiation, allowing for automated and efficient attachment, even when the sponge is folded, utilizing a maneuvering mechanism and UV emitting device.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If manual sewing is used to attach RE tags to sponge items, then the tag can be securely attached, but the process is time-consuming and increases operational costs

Engineering Contradiction:

Improvetag attachment securityVSAvoidattaching process time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent replaces the mechanical sewing process with an adhesive bonding system. The adhesive material is applied to the tag or sponge, and the attachment is cured using ultraviolet radiation, eliminating the need for manual or automated sewing mechanisms.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the attachment mechanism from mechanical (sewing) to chemical (adhesive bonding). The adhesive material undergoes a chemical transformation when exposed to ultraviolet radiation, curing from a liquid or soft state to a solid, rigid bond state.

Inventive Principle:

Principle #35Parameter changes

2Manufacturing precision

If different sewing machines are used for different sponge sizes, then each sponge type can be properly sewn, but the device complexity and cost increase

Engineering Contradiction:

Improvetag attachment accuracyVSAvoidsewing machine variety

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The patent creates a universal attachment system that works for all sponge sizes and types. A single adhesive material formulation and UV curing process can be applied to tags on sponges of varying dimensions, eliminating the need for size-specific sewing machines.

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The adhesive material's properties are adjusted to provide universal applicability across different sponge sizes. The UV-curable adhesive maintains consistent bonding characteristics regardless of the substrate size, allowing one formulation to serve multiple applications.

Inventive Principle:

Principle #35Parameter changes

3Measurement precision

If X-ray machines are used to detect sponge items, then sponge items can be detected, but the machine cannot distinguish one sponge item from several items and requires rescanning

Engineering Contradiction:

Improvesponge item detectionVSAvoidindividual sponge identification

Core Design Contradiction:

Measurement precisionVSLoss of information

Solution Approach 1:

The patent uses RF tags with unique identifiers that can be detected and distinguished individually. Each tag acts as a unique signal source, allowing the system to identify and track individual sponge items without confusion, unlike X-ray which sees only density contrasts.

Inventive Principle:

Principle #32Color changes

4Productivity

If adhesive material is applied to the tag before attachment, then the tag is ready for immediate bonding, but the adhesive may interfere with tag functionality

Engineering Contradiction:

Improveattachment speedVSAvoidtag functionality

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The adhesive material is applied selectively to specific areas of the tag or sponge where bonding is needed, rather than coating the entire tag surface. This ensures that adhesive does not interfere with RF tag functionality while still providing sufficient bonding area.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The patent uses UV-curable adhesive that remains in a non-interfering state until activation. The adhesive is applied in a form that does not affect tag electronics, then UV radiation triggers rapid curing to create the bond, minimizing the time the adhesive is in a potentially interfering state.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This solution provides a cost-effective, automated, and biocompatible method for attaching RF tags to sponge items, ensuring accurate tracking and reducing the risk of items being left inside patients, while maintaining sterilization requirements.

Implementation Method 1

The adhesive material is cured by ultraviolet radiation

Methodology Applied

Scientific EffectUltraviolet radiation curing: Photopolymerisation

Data Source

PatentUS9289943B2Apparatus and method for attaching an RF tag to a sponge item

Publication Date: 2016.03.22 STERIS CORP

AI summary

The subject matter discloses a method of attaching a tag to a disposable item such as a sponge, the method comprising obtaining a tag and a disposable item; attaching the tag to the disposable item using an adhesive material. The adhesive material is cured by ultraviolet radiation. The method also comprises applying the ultraviolet radiation on the tag attached on the disposable item. The tag may be an RE tag.