Ultrasonic Blade Coating and Lumen Design for Mist Reduction
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Solution Overview
Problem
Ultrasonic surgical instruments face challenges in reducing the mist plume formed when the distal end of the blade contacts fluids during procedures, which limits visibility at the surgical site.
Innovation Solution
The ultrasonic blades are designed with features such as a tapered concave surface, a tip coating, a lumen fluidically coupled to a spraying mechanism, or a material that holds an electric charge to minimize the mist plume by either converging or repelling fluid droplets, thereby improving visibility.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If the distal end of the ultrasonic blade contacts fluid during surgical procedures, then cutting and coagulation functions are performed, but a fine mist plume is generated that limits visibility at the surgical site
Solution Approach 1:
The patent applies the principle of converting harm into benefit by using the ultrasonic vibrations that naturally cause mist generation to instead coalesce and repel fluid droplets. The ultrasonic energy that would normally atomize fluid into a mist plume is harnessed to create a cleaning effect that repels fluid from the blade surface, thereby converting the harmful mist-generating vibration into a beneficial fluid-repelling mechanism that improves visibility.
Solution Approach 2:
The patent changes the physical parameters of the blade surface by applying a hydrophobic coating that alters surface energy characteristics. This parameter change in surface properties causes fluid droplets to bead up and repel rather than spread and atomize, fundamentally changing the interaction between the blade and fluid to reduce mist plume generation.
2Device complexity
If a single-element end effector is used, then the instrument structure is simplified, but the ability to apply blade-to-tissue pressure is limited
Solution Approach 1:
The patent divides the end effector into multiple elements - specifically a blade element and a clamp element - that can move relative to each other. This segmentation allows the clamp to apply independent pressure to the tissue while the blade performs cutting or coagulation, thereby increasing the force available without significantly complicating the overall instrument structure.
3Force
If multiple-element end effectors with clamping mechanism are used, then blade-to-tissue pressure is improved, but the device complexity increases
Solution Approach 1:
The patent merges the cutting/coagulation function and the clamping function into a single integrated end effector assembly that operates as one unit. The blade and clamp are positioned and configured to work together simultaneously, eliminating the need for separate clamping devices and reducing overall system complexity while maintaining the force advantages of multiple elements.
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
These features effectively reduce the mist plume, enhancing visibility during surgical procedures by either converging fluid droplets or repelling them from the blade surface, thus improving the clarity of the surgical site.
Implementation Method 1
Ultrasonic vibrations, when transmitted to organic tissue at suitable energy levels and using a suitable end effector, may be used to cut, dissect, or coagulate tissue
Implementation Method 2
The transducer may be constructed of one or more piezoelectric or magnetostrictive elements in the instrument hand piece
Implementation Method 3
The transducer may be constructed of one or more piezoelectric or magnetostrictive elements in the instrument hand piece
Implementation Method 4
At least a portion of the body comprises at least one layer of a first material to globalize fluid particles in contact therewith
Implementation Method 5
a material that holds an electric charge to minimize the mist plume by either converging or repelling fluid droplets
Data Source
AI summary
A surgical instrument includes a transducer configured to produce vibrations at a predetermined frequency. The transducer is configured to produce vibrations at a predetermined frequency. An ultrasonic blade extends along the longitudinal axis and is coupled to the transducer. The ultrasonic blade includes a body having a proximal end and a distal end. The distal end is movable relative to the longitudinal axis by the vibrations produced by the transducer. The body includes a treatment region that extends from the proximal end to the distal end. The body includes surface coatings to prevent the formation of a thin layer of fluid on the body which may be atomized thus creating a mist. The body may also include a bore configured to emit a spray which will also prevent the formation of thin layer of fluid on the body.