Two-Step Silicone Coating for Surgical Needles
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Solution Overview
Problem
Conventional batch dip coating processes for surgical needles result in long cure times, susceptibility to contamination, and adhesion issues between needles, leading to compromised coating integrity and performance.
Innovation Solution
A novel batch silicone coating process involving a porous containment vessel where needles are immersed in a platinum-catalyzed silicone coating solution, partially cured at a lower temperature to allow mechanical separation, and then fully cured at a higher temperature to prevent adhesion and enhance coating durability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional batch dip coating processes are used for surgical needles, then coating application is achieved, but cure time is excessively long and contamination susceptibility increases
Solution Approach 1:
The patent applies parameter changes by modifying the chemical composition of the coating system - specifically using a two-component silicone system with a catalyst that enables rapid curing. This chemical parameter change reduces cure time from conventional extended periods to just minutes while maintaining coating integrity and performance.
Solution Approach 2:
The patent employs a disposable porous containment vessel (such as a foam basket) that is used once and then discarded. This eliminates the need for cleaning and reusing coating baskets, thereby preventing contamination accumulation and reducing cure time by allowing direct transfer to curing trays without intermediate handling steps.
2Productivity
If needles are coated in batch and cured while in contact, then production efficiency is maintained, but adhesion between needles compromises coating integrity
Solution Approach 1:
The patent applies preliminary action by pre-forming the coating on the needles while they are in contact within the porous containment vessel, then transferring the entire batch to curing trays before the coating adheres the needles together. This timing intervention prevents adhesion problems while maintaining batch processing efficiency.
Solution Approach 2:
The porous containment vessel acts as an intermediary that holds the needles in a controlled arrangement during coating application, then allows easy transfer to curing trays. This intermediary structure prevents direct needle-to-needle adhesion during the critical coating and transfer phases while maintaining production efficiency.
3Ease of manufacture
If conventional coating baskets are reused, then cost is reduced, but contamination accumulates and compromises coating quality
Solution Approach 1:
The patent employs disposable porous containment vessels made from inexpensive materials like foam that can be discarded after a single use. This eliminates contamination accumulation from basket reuse while keeping costs low due to the inexpensive nature of the disposable vessels.
Solution Approach 2:
The porous containment vessel provides a controlled, inert environment during the coating process that prevents contamination of the coating solution and needles. The porous structure allows uniform coating distribution while isolating the needles from external contaminants.
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 process improves coating integrity, reduces visual defects, and enhances needle performance by preventing adhesion and ensuring consistent, effective lubrication, thereby reducing penetration force and increasing yield.
Implementation Method 1
A plurality of surgical needles is provided. A silicone coating solution is applied to the plurality of needles. The silicone coating solution includes a platinum catalyst and a silicone compound curable by cross-linking to provide a coating on each needle.
Implementation Method 2
The silicone compound curable by cross-linking to provide a coating on each needle
Implementation Method 3
The coatings on the needles are partially cured at a first temperature for a sufficient time such that there is weak needle-to-needle adhesion.
Implementation Method 4
The needles are then mechanically separated and the coatings on the needles are fully cured at a second temperature for a sufficient time, the second temperature being higher than the first temperature.
Data Source
AI summary
A novel two-step process for batch coating surgical needles with cross-linked silicone coatings is disclosed. The surgical needles are cured using a two-step process. The coatings on the needles are partially cured in the first step and mechanically separated. The coatings on the needles are then fully cured in the second step.