Surgical Needle Coating Sequence to Avoid Laser-Drilling Charring
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Solution Overview
Problem
Surgical needles face issues with lubricity loss and charring during laser drilling, leading to reduced performance and visual defects due to the energy required for the process.
Innovation Solution
A system comprising a first coating system for applying a primer and base coat, followed by a laser drilling process to create a suture attachment end, and a second coating system for applying a top coat using a basket with a drainage area to manage excess coating, ensuring the top coat is applied after the suture attachment end is formed, thereby avoiding charring and maintaining lubricity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If lubricious coatings are applied to surgical needles prior to laser drilling, then the needles have suitable lubricity for tissue contact, but the coatings char during laser drilling leading to gumming/fouling of cutoff dies and visual defects
Solution Approach 1:
The patent applies primer and base coats to the needle blank before laser drilling to prepare the surface, then applies the top lubricious coat after laser drilling to avoid charring while maintaining lubricity
Solution Approach 2:
The coating process is divided into three distinct stages: primer coat applied before drilling, base coat applied before drilling, and top coat applied after drilling. This segmentation allows each coating to serve its specific function without interfering with the laser drilling process
2Productivity
If coatings are applied before laser drilling, then the manufacturing process is more efficient, but the coatings suffer from charring and loss of lubricity
Solution Approach 1:
The primer and base coats are applied in advance before laser drilling to prepare the surface and provide adhesion, while the critical top coat is applied after drilling to ensure it is not exposed to damaging laser energy
Solution Approach 2:
Different parts of the manufacturing process receive different treatments: the primer and base coats withstand the laser drilling process, while the top coat is protected from the laser by being applied afterward, ensuring each coating has the appropriate properties for its intended function
3Ease of manufacture
If a basket with drainage area is used for top coat application, then excess coating is effectively managed, but the device complexity increases
Solution Approach 1:
The basket is constructed with porous material that allows excess top coat to drain through during the dip coating process, effectively managing excess coating while maintaining a relatively simple overall device structure
Solution Approach 2:
The porous basket acts as an intermediary between the top coat solution and the needle, allowing controlled passage of excess coating material while supporting the needle during the coating process
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 solution maintains the lubricity and aesthetic appearance of surgical needles, providing a consistent tissue-penetrating force and reduced drag force, even after multiple uses, by applying the top coat post-laser drilling and utilizing a basket for efficient coating management.
Implementation Method 1
The laser drilling system can be configured to create a suture attachment end within a second portion of the surgical needle blank
Implementation Method 2
The system can include a first drying system that can be configured to remove at least a portion of excess top coat from the surgical needle. In one aspect, the drying system can include a vacuum drying chamber. In other aspects, the system can include a second drying system that can be configured to remove at least a portion of solvent from the top coat
Data Source
AI summary
Systems and methods for coating surgical needles are provided.