Selective Coating Removal on Surgical End Effectors for RF Sealing

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Solution Overview

Problem

Existing surgical instruments with tissue cutting and RF energy application face issues of tissue sticking and low burst pressure due to the use of coating layers on tissue-contacting surfaces, which compromise surgical efficiency and sealing effectiveness.

Innovation Solution

The application of a hydrophobic coating on tissue-contacting surfaces followed by selective removal of portions of the coating using mechanical tools or powder blasting techniques to enhance anti-sticking performance while improving burst pressure.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Object-affected harmful factors

If a coating layer is applied to the tissue-contacting surface, then tissue anti-sticking properties are improved, but burst pressure decreases

Engineering Contradiction:

Improvetissue stickingVSAvoidburst pressure

Core Design Contradiction:

Object-affected harmful factorsVSStrength

Solution Approach 1:

The patent applies different surface properties to different regions of the tissue-contacting surface. The coating is selectively removed to create zones with different characteristics: coated areas provide anti-sticking properties while uncoated areas maintain high burst pressure. This local differentiation allows the surface to simultaneously achieve both anti-sticking and high burst pressure capabilities.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The coating layer is divided into multiple segments through selective removal, creating a patterned surface with alternating coated and uncoated regions. This segmentation allows the surface to exhibit both anti-sticking properties (in coated regions) and high burst pressure (in uncoated regions), resolving the contradiction between these two properties.

Inventive Principle:

Principle #1Segmentation

2Object-affected harmful factors

If a coating layer is applied to the tissue-contacting surface, then anti-sticking performance is improved, but RF energy transmission is impeded

Engineering Contradiction:

Improvetissue stickingVSAvoidRF energy transmission

Core Design Contradiction:

Object-affected harmful factorsVSUse of energy by moving object

Solution Approach 1:

The patent creates local variations in coating presence across the tissue-contacting surface. Areas without coating allow efficient RF energy transmission, while coated areas provide anti-sticking properties. This local differentiation enables the surface to simultaneously facilitate both RF energy transmission and prevent tissue sticking.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The coating is segmented into removed and retained portions, creating zones that differentially affect RF energy transmission and tissue sticking. The uncoated segments allow RF energy to pass through effectively, while coated segments provide anti-sticking protection, thus resolving the contradiction between these two functions.

Inventive Principle:

Principle #1Segmentation

3Object-affected harmful factors

If a coating layer is applied to the tissue-contacting surface, then protein bonding is reduced, but sealing effectiveness is compromised

Engineering Contradiction:

Improveprotein bondingVSAvoidsealing effectiveness

Core Design Contradiction:

Object-affected harmful factorsVSReliability

Solution Approach 1:

The patent creates local quality variations by selectively removing coating in specific regions. Areas without coating provide strong sealing effectiveness, while coated areas reduce protein bonding. This spatial differentiation allows the surface to simultaneously achieve both reduced protein bonding and effective sealing.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The coating is segmented into removed and retained portions, creating functional zones: uncoated segments provide effective sealing while coated segments reduce protein bonding. This segmentation resolves the contradiction by allowing different regions to fulfill different functions simultaneously.

Inventive Principle:

Principle #1Segmentation

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 method improves tissue anti-sticking properties and burst pressure, ensuring better surgical efficiency and sealing performance by allowing RF energy to pass through or be less impacted by the coating, thereby reducing protein bonding sites.

Implementation Method 1

Methodology Applied

Scientific EffectHydrophobic effect: Hydrophobe

Implementation Method 2

selective removal of portions of the coating using mechanical tools or powder blasting techniques

Methodology Applied

Scientific EffectAbrasion: Abrasion

Implementation Method 3

allowing RF energy to pass through or be less impacted by the coating

Methodology Applied

Scientific EffectElectrical conduction: Conduction (electrical)

Data Source

PatentUS20260026835A1End effector with selectively removed coating for applying electrical energy and related methods

Publication Date: 2026.01.29 CILAG GMBH INTERNATIONAL

AI summary

A method of manufacturing a surgical instrument that includes a tissue contacting surface operable to apply ultrasonic energy or RF energy to tissue. The method includes applying a hydrophobic coating that includes silicone to a base surface of the tissue contacting surface to form an applied coating layer having a coating application thickness. The method also includes removing portions of the applied coating layer with a resiliently biased mechanical coating removal tool to form a plurality of removed portions of coating. A removal depth of each removed portion of the plurality of removed portions can each be from 50% to 100% of the coating application thickness such that from 10% to 50% of the applied coating layer is removed from the base surface.