Ultrasonic Medical Device Coating Thickness Optimization
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Solution Overview
Problem
Existing ultrasonic surgical devices face challenges in effectively preventing thermal invasion and electrical leakage during tissue treatment, particularly due to differences in linear expansion coefficients between metal vibration transmission members and resin coatings, leading to potential peeling off of coatings at high kinetic energy areas.
Innovation Solution
A medical device with a vibration transmission member coated with a first layer of sufficient thickness for heat and electrical insulation at node positions and a second layer of smaller thickness at distal ends, where kinetic energy is high, to prevent peeling and ensure durability and reduced invasiveness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a uniform thick coating is applied to the entire vibration transmission member, then heat and electrical insulation are improved, but coating peeling occurs at high kinetic energy areas due to linear expansion coefficient differences
Solution Approach 1:
The patent applies different coating thicknesses to different locations on the vibration transmission member. Specifically, the coating is applied thicker at the distal end (high kinetic energy area) and thinner at the proximal end (low kinetic energy area). This local differentiation resolves the contradiction by providing sufficient insulation where needed while preventing peeling in high-stress regions through reduced coating mass.
Solution Approach 2:
The patent changes the parameter of coating thickness from a uniform value to a spatially varying value. The coating thickness is optimized as a function of position along the vibration transmission member, with maximum thickness at the distal end and minimum thickness at the proximal end. This parameter optimization simultaneously achieves insulation requirements and adhesion constraints.
2Object-affected harmful factors
If a thick coating is applied to maintain insulation at node positions, then thermal invasion prevention is improved, but coating durability deteriorates at distal ends with high kinetic energy
Solution Approach 1:
The patent recognizes that different locations on the vibration transmission member have different requirements. The distal end requires thick coating for thermal insulation, while the proximal end requires thin coating for durability. By applying local quality differentiation, the patent satisfies both insulation and durability requirements simultaneously.
Solution Approach 2:
The patent applies coating selectively with varying thickness rather than uniformly. The coating is applied excessively (thickly) only where thermal protection is critical (distal end), and minimally (thinly) where durability is the primary concern (proximal end). This partial application strategy optimizes the balance between protection and durability.
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 device effectively prevents thermal invasion and electrical leakage, maintaining insulation and durability by optimizing coating thicknesses to match energy distribution, thus minimizing invasiveness during tissue treatment.
Implementation Method 1
The ultrasonic surgical blade uses an ultrasonic transducer to generate mechanical vibration by ultrasonic frequencies and transmit the mechanical vibration to an end effector via a transmitting element
Implementation Method 2
By a vibration motion of the end effector, heat is generated in the tissue to incise and coagulate the tissue
Data Source
AI summary
A medical device according to one embodiment of the present invention includes: a vibration transmission member that comprises a node position of vibration and an area including the node position and a portion at a distal end side relative to the node position, and to which the vibration is transmitted; a first coating that covers a side of the node position of the area; and a second coating that covers a distal end side relative to the first coating of the area and has a thickness smaller than that of the first coating.