U.S. patent application number 13/776411 was filed with the patent office on 2013-08-29 for coating suitable for surgical instruments.
This patent application is currently assigned to Team Medical, LLC. The applicant listed for this patent is Team Medical, LLC. Invention is credited to James Brassell, Warren P. Heim.
Application Number | 20130226175 13/776411 |
Document ID | / |
Family ID | 38309955 |
Filed Date | 2013-08-29 |
United States Patent
Application |
20130226175 |
Kind Code |
A1 |
Heim; Warren P. ; et
al. |
August 29, 2013 |
COATING SUITABLE FOR SURGICAL INSTRUMENTS
Abstract
A coating and devices using the coating are provided. The
coating is applied in liquid form and dried or otherwise cured to
form a durable adherent coating resistant to high temperatures and
having optional hydrophobic properties. The coating formulation
contains an aqueous formulation of silica, one or more fillers, and
sufficient base, (e.g., potassium hydroxide), to have a pH
exceeding about 10.5 during at least part of the formulation
process. The formulation may contain a compound(s) that affects
surface free energy, energy to make the cured coating hydrophobic.
Such compounds include silanes containing halogens (e.g., fluorine
or chlorine) and in particular silanes containing one or more
hydrolyzable groups attached to at least one silicon atom and a
group containing one or more halogens (e.g., chlorine or fluorine).
A medical instrument (e.g., electrosurgical instrument) may be at
least partially covered by a coating using the formulation.
Inventors: |
Heim; Warren P.; (Boulder,
CO) ; Brassell; James; (Boulder, CO) |
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Applicant: |
Name |
City |
State |
Country |
Type |
Team Medical, LLC; |
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US |
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Assignee: |
Team Medical, LLC
Boulder
CO
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Family ID: |
38309955 |
Appl. No.: |
13/776411 |
Filed: |
February 25, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13398543 |
Feb 16, 2012 |
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13776411 |
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12768962 |
Apr 28, 2010 |
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13398543 |
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11627340 |
Jan 25, 2007 |
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12768962 |
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60762375 |
Jan 25, 2006 |
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Current U.S.
Class: |
606/45 ;
106/286.7; 106/287.16; 427/2.1; 524/544; 524/546 |
Current CPC
Class: |
A61B 2018/00601
20130101; B05D 3/007 20130101; A61L 31/14 20130101; B05D 5/00
20130101; A61L 2420/08 20130101; C09D 1/00 20130101; A61L 31/088
20130101; C04B 24/42 20130101; B05D 1/36 20130101; C04B 28/26
20130101; A61L 2420/02 20130101; H01B 3/445 20130101; C04B
2111/00525 20130101; A61L 2420/06 20130101; Y02W 30/94 20150501;
C04B 2111/00482 20130101; A61B 18/00 20130101; Y10T 428/259
20150115; A61B 2017/00526 20130101; Y02W 30/91 20150501; A61B 18/14
20130101; C04B 2111/00836 20130101; C04B 28/26 20130101; C04B 14/06
20130101; C04B 14/30 20130101; C04B 14/303 20130101; C04B 14/305
20130101; C04B 14/322 20130101; C04B 14/325 20130101; C04B 14/366
20130101; C04B 18/146 20130101; C04B 24/42 20130101; C04B 40/0263
20130101; C04B 2103/40 20130101; C04B 28/26 20130101; C04B 14/06
20130101; C04B 14/30 20130101; C04B 14/303 20130101; C04B 14/305
20130101; C04B 14/322 20130101; C04B 14/323 20130101; C04B 14/324
20130101; C04B 14/325 20130101; C04B 14/328 20130101; C04B 14/366
20130101; C04B 18/146 20130101; C04B 24/2682 20130101; C04B 24/42
20130101; C04B 2103/40 20130101 |
Class at
Publication: |
606/45 ; 524/546;
524/544; 106/286.7; 106/287.16; 427/2.1 |
International
Class: |
A61B 18/00 20060101
A61B018/00; C09D 1/00 20060101 C09D001/00; H01B 3/44 20060101
H01B003/44 |
Claims
1. A surgical instrument for receiving electrosurgical energy,
wherein at least part of said instrument is insulated with a
coating having a substantially non-stick coating formulation
comprising: silica; at least one inorganic filler; and a strong
base in an amount so that the coating formulation has a pH of at
least 10.5 during at least part of a formulation process.
2.-18. (canceled)
19. The surgical instrument of claim 1, wherein the instrument is a
blade.
20. The surgical instrument of claim 19, wherein at least part of
the coating is between about 0.001 and 0.1 inches thick.
21. The surgical instrument of claim 20, wherein at least part of
the coating is between about 0.002 and 0.010 inches thick.
22. The surgical instrument of claim 19, wherein a portion of the
blade has an impedance of less than about 5,000 ohms, said portion
comprised of an edge exposed through the coating.
23. The surgical instrument of claim 19, wherein at least a portion
of said blade is composed of stainless steel.
24. The surgical instrument of claim 1, wherein the instrument has
at least a portion with an impedance less than about 5,000
ohms.
25. The surgical instrument of claim 24, wherein at least part of
the coating is between about 0.001 and 0.1 inches thick.
26. The surgical instrument of claim 1, wherein said strong base is
potassium hydroxide.
27. The surgical instrument of claim 1, wherein said coating
formulation has a pH of at least 12.5 during at least part of a
formulation process.
28. The surgical instrument of claim 1, the coating formulation
further comprising: at least one alkoxy silane.
29. The surgical instrument of claim 28, wherein said at least one
alkoxy silane of the formulation comprises at least one
alkylalkoxysilane.
30. The surgical instrument of claim 29, wherein said at least one
alkylalkoxysilane of the formulation includes at least one halogen
being at least one of: chlorine; and fluorine.
31. The surgical instrument of claim 30, wherein said at least one
alkylalkoxysilane of the coating formulation is selected from a
group consisting of: fluoroalkylalkoxysilanes; and
chloroalkylalkoxysilanes.
32. The surgical instrument of claim 31 wherein said
fluoroalkylalkoxysilane is between 5 and 15 weight percent of the
coating formulation.
33. The surgical instrument of claim 1, wherein the coating
formulation further comprises at least one of the following: a
material including a fluorinated carbon chain; and a material
including at least partially hydrolyzed fluorinated silanes; and a
material including at least partially cross-linked hydrolyzed
silanes.
34. The surgical instrument of claim 31, wherein said at least one
alkylalkoxysilane of the coating formulation comprises at least one
hydrolyzable inorganic alkylsilyl group.
35. The surgical instrument of claim 34, wherein said hydrolyzable
inorganic alkylsilyl of the coating formulation group is selected
from a group consisting of: a methoxysilyl group; and an
ethoxysilyl group.
36. The surgical instrument of claim 1, wherein said coating
formulation comprises at least 10 weight percent of a solution
comprising a colloidal silicate.
37. The surgical instrument of claim 36, wherein said solution of
the coating formulation comprises an alkali metal silicate
solution.
38. The surgical instrument blade of claim 19, wherein said coating
formulation comprises at least 10 weight percent of a solution
comprising a colloidal silicate.
39. The surgical instrument of claim 1, wherein said inorganic
filler of the coating formulation comprises at least one metal and
at least one non-metal material selected from a group consisting
of: aluminum oxides; zirconium nitrides; zirconium carbides; boron
carbides; silicon oxides; magnesium-zirconium oxides;
zirconium-silicon oxides; titanium oxides; tantalum oxides;
tantalum nitrides; tantalum carbides; silicon nitrides; silicon
carbides; tungsten carbides; titanium nitrides; titanium carbides;
nibobium nitrides; niobium carbides; vanadium nitrides; vanadium
carbides; and hydroxyapatite.
40. The surgical instrument of claim 1, wherein said inorganic
filler of the coating formulation comprises one or more materials
that have at least 30 percent by weight A1 2O3 or SiO2 either alone
or combined with other elements.
41. The surgical instrument of claim 1, wherein said inorganic
filler of the coating formulation comprises one or more materials
that are clays from the smectite group of phyllosilicate
minerals.
42. The surgical instrument of claim 41, wherein said smectite clay
is an onium ion treated clay.
43. The surgical instrument of claim 42, wherein said onium ion
treated clay is onium ion treated montmorillonite.
44. The surgical instrument of claim 1, wherein said inorganic
filler of the coating formulation comprises one or more materials
from a group consisting of: talc, kaolin, mica, smectite,
montmorillonite, sericite, and hectorite.
45. The surgical instrument of claim 1, wherein said inorganic
filler of the coating formulation has at least one filler material
with at least one dimension, such as diameter, length, width, or
particle size, having a mean value of less than about 200
micrometers.
46. The surgical instrument of claim 1, the coating formulation
further comprising: at least one fluoropolymer.
47. The surgical instrument of claim 46, wherein said at least one
fluoropolymer is at least one of PTFE and PFA.
48. The surgical instrument of claim 47, wherein said at least one
of PTFE and PFA is an aqueous dispersion of at least one of PTFE
and PFA.
49. The surgical instrument of claim 1, wherein the coating has a
surface free energy of less than about 32 millinewtons/meter.
50. A process of manufacturing a surgical instrument in which at
least one apparatus metal component surface is coated at least in
part with a material that produces a substantially non-stick
coating formulation comprising: preparing a coating comprising:
silica; at least one inorganic filler; at least one hydrolyzable
inorganic alkylsilyl; and a strong base in an amount so that the
coating formulation has a pH of at least 10.5 during at least part
of a formulation process, wherein said base comprises potassium
hydroxide; applying the coating to at least a portion of a one
metal component surface; drying the coating at about 60 to 200
degrees Fahrenheit; curing the coated part at a temperature greater
than about 350 degrees Fahrenheit.
51. The process of claim 50, wherein said at least one hydrolyzable
inorganic alkylsilyl contains at least one halogen.
52. The process of claim 51, wherein said at least one halogen is
comprised of at least one of: chlorine; and fluorine.
53. The process of claim 50, wherein said coating formulation has a
pH of at least 12.5 during at least part of the formulation
process.
Description
RELATED APPLICATIONS
[0001] This is a continuation of U.S. patent application Ser. No.
13/398,543, filed Feb. 16, 2012, entitled "COATING SUITABLE FOR
SURGICAL INSTRUMENTS," which application claimed priority to U.S.
patent application Ser. No. 12/768,962 filed Apr. 28, 2010,
entitled "COATING SUITABLE FOR SURGICAL INSTRUMENTS," which
application claimed priority to U.S. patent application Ser. No.
11/627,340 filed Jan. 25, 2007, entitled "COATING SUITABLE FOR
SURGICAL INSTRUMENTS," which application claimed priority to U.S.
Provisional Patent Application No. 60/762,375 filed Jan. 25, 2006,
entitled "COATING FOR SURGICAL INSTRUMENTS AND RELATED METHODS AND
APPARATUS," each of which applications are incorporated herein by
reference in their entirety.
FIELD OF THE INVENTION
[0002] The present invention relates to materials' coatings and
using coatings to protect and affect the surface properties of
products or apparatus at least partially covered with such
coatings, such as instruments used during surgical procedures. The
invention may be used in applications where coatings are useful and
more particularly for applications benefitting from containing one
or components containing materials benefitting from protecting the
component from the use environment or the use environment from the
component. Examples of such protection are protecting components
from high temperatures, liquids or vapors, such as moisture or
steam, or protecting materials in the use environment from high
temperature components. The invention is advantageous where an
adherent coating able to withstand high temperatures, such as a
coating being adherent to metals, protects components from the use
environment or protects elements of the use environment from
components. An example of such use is on instruments that apply
electrosurgical power to a tissue site to achieve a predetermined
surgical effect. Another example of such use is coating engine
exhaust components such as mufflers. Another example of such use is
coating doors to improve thermal or oxidative resistance, such as
fire doors. Aspects of the present invention include a composition
for coating formulation, a method for preparing the composition,
and a method for forming a coating using the composition.
BACKGROUND OF THE INVENTION
[0003] Electrical energy is widely employed during surgical
procedures in which electrosurgical techniques are employed to
provide localized high flux energy to tissue during open,
laparoscopic, and arthroscopic applications to provide clinical
benefits, such as hemostasis, relative to surgical approaches that
use mechanical cutting such as scalpels. Electrosurgical techniques
typically entail the use of a hand-held instrument, or pencil, that
transfers alternating current electrical power operating at radio
frequency (RF) to tissue at the surgical site. The time-varying RF
electrical power yields a predetermined electrosurgical effect,
such as tissue cutting or coagulation.
[0004] The process of applying RF electrical power causes high
temperatures to occur in the tissue and on at least part of the
surgical instrument. The result of these high temperatures is the
formation of tissue fragments and other substances that often
accumulate and form deposits on surgical instruments. These
deposits are called eschar. Eschar frequently accumulates in such
amounts that it interferes with surgical procedures.
[0005] In attempts to alleviate the formation of eschar or make
instruments from which eschar may be more easily removed than from
metal surfaces, instruments with surface coatings, such as coated
blades, have been used or described. For example, such coatings are
made from materials to which eschar accumulations stick less
tightly than they stick to the metals from which electrosurgical
instruments are made. The coatings are typically made from one or
more polydiorganosiloxane or polytetrafluorethylene (PTFE)
compounds. These compounds suffer from not having high temperature
durability. Materials capable of withstanding high temperatures,
such as ceramics, do not confer adequate non-stick properties when
used as coatings. In this regard, the present inventors have
recognized that the need exists for a high temperature coating that
has non-stick properties.
[0006] Relatedly, the metal conductors in electrosurgical
instruments that convey energy to tissue get hot during use. When
contacting tissue the hot surfaces damage tissue. Therefore,
protecting tissue in the use environment from the hot instrument
surfaces can reduce tissue damage. Typical coatings cannot
withstand the high temperatures in regions directly adjacent to
where RF electrical power transfers to tissue. In this regard, the
present inventors have also recognized that the need exists for a
high temperature coating with insulating properties.
[0007] In general, the present inventors believe that the need
exists for a coating that can protect component materials from the
use environment and the use environment from components.
SUMMARY OF THE INVENTION
[0008] Accordingly, an objective of the present invention is to
provide a coating formulation, method for preparing the coating
formulation, and method for applying the coating formulation to one
or more components in an apparatus that needs protection from the
use environment or that needs to have the use environment protected
from the apparatus.
[0009] An objective of the present invention is to provide a
coating formulation, method for preparing the coating formulation,
and method for applying the coating formulation to one or more
components of devices used in surgical environments.
[0010] An objective of the present invention is to provide a
coating formulation, method for preparing the coating formulation,
and method for applying the coating formulation to one or more
components of devices used in surgical environments that results in
a durable high temperature nonstick coating.
[0011] Another objective of the present invention is to provide a
coating formulation, method for preparing the coating formulation,
and method for applying the coating formulation to a surgical
instrument powered by electrosurgical energy that results in
reduced eschar accumulation.
[0012] In addressing these objectives, the present inventors have
recognized that a novel coating formulation containing silica
(e.g., colloidal and/or amorphous silica), inorganic fillers, and a
strong base such that the pH of the formulation exceeds 10.5 during
at least part of the preparation process produces a durable
adherent high temperature coating to which a treatment such as a
non-stick outer coating may be applied. In this regard, the use of
a strong base advantageously serves to at least partially dissolve
the silica.
[0013] In one aspect, the present inventors have further recognized
that a novel coating containing silica (e.g., colloidal and/or
amorphous silica), inorganic fillers, and a strong base such that
the pH of the formulation exceeds 10.5 during at least part of the
preparation process, and which additional constituents such as
alkoxy silanes may be added, produces a coating that is inherently
non-stick, adherent, durable, and capable of withstanding high
temperatures. The present inventors have further recognized that
such coatings have non-stick properties when the formulation
contains one or more halogen-containing alkylalkoxysilanes, e.g.,
those containing halogens such as fluorine or chlorine. In the
latter regard, and by way of example, fluoroalkylalkoxysilanes or
chloroalkylalkoxysilanes may be employed.
[0014] The present inventors have yet further recognized that such
use of alkylalkoxysilanes possessing hydrolyzable inorganic
alkylsilyl groups including methoxysilyl or ethoxysilyl groups
produces durable high temperature coatings. The present inventors
have yet further recognized that using alkylalkoxysilanes
possessing hydrolyzable inorganic alkylsilyl groups including
methoxysilyl or ethoxysilyl groups and one or more straight or
branched halogenalkyl chains, such as chloroalkyl or fluoroalkyl
chains, produces durable high temperature coatings with excellent
hydrophobic and oleophobic (non-stick) properties.
[0015] The present inventors have yet further recognized that a
coating containing silica (e.g., colloidal and/or amorphous
silica), inorganic fillers, and a strong base such that the pH of
the formulation exceeds 10.5 during at least part of the
formulation process to which one or more substance containing one
or more fluorinated carbon chains, such as PTFE emulsions or at
least partially hydrolyzed fluorinated silanes or at least
partially cross-linked hydrolyzed silanes, form a coating that is
inherently non-stick, adherent, durable, and capable of
withstanding high temperatures.
[0016] In another aspect, the present inventors have further
recognized that adding materials such as water, surfactants, and
solids such as fumed silica alter the viscosity and surface tension
of the formulation to allow it to flow or otherwise cover surfaces
producing coatings having different thicknesses or surface finishes
and making coatings suitable for various application methods such
as dipping or spraying.
[0017] In further addressing the objectives of the present
invention the inventors have recognized that the coating
formulation of the present invention may be applied to organic and
inorganic materials, such as cloth, glass, plastic, and metal
materials and produce durable adherent coatings. Such coating may
be restricted to the surface or may penetrate into interstitial
pores, cracks, crevices, or other voids that exist.
[0018] In further addressing the objectives of the present
invention the inventors have recognized that the coating
formulation of the present invention may be applied to electrically
conductive metal surfaces and produce durable adherent coatings
suitable for use on medical instruments including instruments
suitable for use with electrosurgery. The present inventors have
further recognized that the coating formulation of the present
invention may be applied to stainless steel and materials having
thermal conductivities greater than stainless steel, such as
molybdenum, and produce durable adherent coatings suitable for
medical instruments including instruments suitable for use with
electrosurgery. The present inventors have further recognized that
surgical instruments comprised at least in part with metals having
coatings based on the formulation of the present invention are most
suitable for use in electrosurgical applications when at least one
part of the metal surface is left uncoated or sufficiently thinly
coated so that an energy transfer path exists with sufficiently low
impedance, less than approximately 5,000 ohms, that electrosurgical
energy can adequately transfer from the surgical instrument to the
tissue where a predetermined surgical effect is desired to
occur.
[0019] In still further addressing the objectives of the present
invention the inventors have recognized that the coating
formulation of the present invention may be applied by dipping,
spraying, painting, printing, pad printing, or other means capable
of transferring a liquid substance to a substrate such as one made
from metal or a surgical instrument. In still further addressing
the objectives for the present invention the inventors have
recognized that the coating formulation of the present invention
may be applied in multiple coats to build up a final coat. The
present inventors have further recognized that such multiple coats
may be applied prior to applying energy to any already applied
coat, such application of energy being applied to cure the coating
material.
[0020] In still further addressing the objectives of the present
invention the inventors have recognized that the coating
formulation of the present invention may be cured by applying
energy, such as thermal energy transferred by conduction from air
or radiation from one or more surfaces, to enhance the properties
of the coating, such as its durability, resistance to moisture,
adherence, and non-stick properties.
[0021] In short, the present inventors have recognized that a
durable coating is needed to improve the performance of apparatus,
such as to prevent or reduce the formation or accumulation of the
deposits that form on material surfaces such as the surfaces of
surgical instruments powered by electrosurgical energy. The present
invention comprises a coating formulation that includes colloidal
silica, a strong base, one or more fillers, and optionally
formulated with one or more substances that produce non-stick
properties to the coating. Such substance that produce non-stick
properties include alkoxy silanes, including alkoxy silanes having
one or more chains containing at least some halogens such as
chlorine or fluorine. The present invention further includes
applying such coating formulations to surfaces to produce a coating
on materials, including materials with organic or inorganic
surfaces, including plastic, glass, and metallic surfaces, that is
adherent, resistant to high temperatures, and non-stick. The
present invention further comprises such metallic surfaces when
they are at least part of a medical instrument, such as an
electrosurgical instrument.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 illustrates one embodiment of a method of preparing
inventive coating formulations in accordance with the present
invention.
[0023] FIG. 2 illustrates one embodiment of a method of coating a
surface of an apparatus coating with an inventive coating
formulation prepared in accordance with the present invention.
[0024] FIG. 3 portrays a cross section of a surgical blade with at
least part of its surface insulated with a coating.
DETAILED DESCRIPTION
[0025] The present invention is for coating formulations capable of
withstanding high temperatures and adherent to metal surfaces and
that may be formulated to have a surface free energy that makes the
surface substantially non-stick, meaning that the surface is
substantially hydrophobic or oleophobic, or both. Such coating
formulations have applicability when used to form a surface coat on
surgical instruments receiving electrosurgical energy and
contacting tissue to achieve a predetermined surgical effect. The
present invention further includes applying the subject coating
formulations and optionally enhancing the coating's properties by
applying energy, such as thermal energy. The coating formulation
comprises a silicate solution, such as a colloidal silicate
solution, one or more fillers, and a strong base and optionally
includes one or more materials that reduce the surface free energy
to enhance the non-stick properties of the surface.
[0026] In one approach, a colloidal silicate solution may contain
at least 10 weight percent silica. In another embodiment the
colloidal silicate solution may contain about 50 weight percent
silica. Representative examples of colloidal silicate solutions are
alkali metal silicates, including those of lithium polysilicate,
sodium silicate, and potassium silicate, and colloidal silica. The
colloidal silicate solution may be colloidal silica with about 50
weight percent silica. The colloidal silica average particle size
may be between about 5 nm and 100 nm and it may be between about 30
and 80 nm and it may be between about 40 and 80 nm. Example
colloidal silica products are Megasol S50 (WesBond Corporation) and
LEVASIL.RTM. 50/50% (N.C. Starck GmbH).
[0027] The coating formulation includes a strong base in a
concentration that causes the pH of the formulation to exceed 10.5
at least at some point during the formulation process. The strong
base functions to at least partially dissolve the silica. For
example, the strong base may be added in sufficient amount to cause
at least the initial pH to exceed 12 and the strong base may be
added to exceed 12.5. The strong base used may be potassium
hydroxide (KOH). The KOH may be added as a KOH solution consisting
of KOH and water and the concentration of the solution may be
approximately 50 weight percent KOH, or between approximately 20
percent and 80 percent.
[0028] The filler material may comprise various metal/non-metal
combinations, including, for example, compositions that comprise
the following: aluminum oxides (e.g., alumina and Al.sub.2
O.sub.3), zirconium oxides (e.g., Zr.sub.2 O.sub.3), zirconium
nitrides (e.g., ZrN), zirconium carbides (e.g., ZrC), boron
carbides (e.g., B.sub.4 C), silicon oxides (e.g., SiO.sub.2), mica,
magnesium-zirconium oxides (e.g., (Mg--Zr)O.sub.3),
zirconium-silicon oxides (e.g., (Zr--Si)O.sub.2), titanium oxides
(e.g., TiO.sub.2) tantalum oxides (e.g., Ta.sub.2 O.sub.5),
tantalum nitrides (e.g., TaN), tantalum carbides (e.g., TaC),
silicon nitrides (e.g., Si.sub.3 N.sub.4), silicon carbides (e.g.,
SiC), tungsten carbides (e.g., WC) titanium nitrides (e.g., TiN),
titanium carbides (e.g., TiC), nibobium nitrides (e.g., NbN),
niobium carbides (e.g., NbC), vanadium nitrides (e.g., VN),
vanadium carbides (e.g., VC), and hydroxyapatite (e.g., substances
containing compounds such as 3Ca.sub.3 (PO.sub.4).sub.2
Ca(OH).sub.2 Ca10(PO.sub.4).sub.6 (OH).sub.2
Ca5(OH)(PO.sub.4).sub.3, and Ca.sub.10 H.sub.2 O.sub.26
P.sub.6).
[0029] Filler materials may be of any shape including, for example,
shapes that approximate in whole or in part or are substantially
fibers, plates, spheres, rods, coils, or polyhedrons such as cubes
or other shapes that may be approximated by a collection of
polygons. Combinations of filler materials having more than one
shape may be used. For example, fillers comprising one or more
materials having fiber shapes and plate-like shapes may be
used.
[0030] The filler may have one or more constituents comprising at
least in part one or more inorganic fibers or inorganic powders
such as those derived from clays with such fillers including those
that contain silicon oxide, aluminum oxides, magnesium oxides,
titanium oxides, chrome oxides, calcium oxides, or zirconium
oxides. The filler materials may contain one or more materials that
have at least 30 percent by weight Al.sub.20.sub.3 or Si0.sub.2
either alone or combined with other elements, such as occurs in
kaolin, talc, or montmorillonite. Clays used may include substances
that are members of the smectite group of phyllosilicate minerals.
Representative examples of clay minerals include bentonite, talc,
kaolin (kaolinite), mica, clay, sericite, hectorite,
montmorillonite and smectite. In the present invention, at least
one of kaolin, talc, and montmorillonite may be used. These clay
minerals can be used singly or in combination.
[0031] The filler may have one or more constituents that are at
least in part fibers that contain in part or wholly alumina or
silica or calcium silicate, such as Wollastonite, alumina fiber,
silica fiber or fibers containing a combination of alumina and
silica.
[0032] At least one dimension, such as diameter, length, width, or
particle size, of at least one of the filler materials may have a
mean value of less than about 200 micrometers. The materials may
have one or more material with one or more dimensions with a mean
value of less than about 50 micrometers. The materials may have one
or more dimensions with one or more mean values less than about 10
microns. The materials may have one or more dimensions with one or
more mean values less than about 5 microns, such as both the
diameter and thickness being less than about 5 microns.
[0033] When montmorillonite is used as a filler it may be a form
that is untreated or it may be a form that has been treated with a
surface modifying process, such as a treatment to enhance its
dispersion. When used, montmorillonite may be a form that has been
onium ion treated. An example onium ion treated montmorillonite is
Nanomer.RTM. 1.44P (Nanocor, Inc.).
[0034] The filler may include at least in part one or more fibers
with mean diameters of between about 1 and 50 .mu.m and it may at
least in part include one or more fibers with mean diameters of
between about 1 and 20 .mu.m. Example fibers include RF 50/99 and
RF 20/99 (Saint-Gobain TM K.K) and Nyglos 2 and Nyglos 4W (Nyco
Minerals, Inc.). The filler may include at least in part a fiber
containing Al.sub.2O.sub.3 and SiO.sub.2 in about equal weight
percentage amounts.
[0035] Substances may be added to promote adhesion or production of
a sealed or hydrophobic surface, including substances that increase
the pH of the mixture as noted above, including sodium hydroxide or
potassium hydroxide, and hydrolyzable silanes that condense to form
one or more cross-linked silicone-oxygen-silicon structures
(siloxane bonds). Example materials are those that use one or more
of the aforementioned colloidal silicates and clays, potassium
hydroxide, and also use one or more substances that reduce the
surface free energy of the surface. Such substances that reduce the
surface free energy include halogenated compounds and fluoropolymer
compounds, such as PTFE and PFA, including aqueous dispersions of
such compounds, organofunctional hydrolyzable silanes, including
those containing one or more fluorine atoms on one or more pendant
carbon chains.
[0036] Among the substances that may be included in the coating
material as one or more hydrolyzable silanes are components having
the general formula R.sub.mSiX.sub.n where R is alkyl chain and X
is hydrolyzable, such a alkoxy group with m and n both integers and
m+n=4. The hydrolyzable silane R may contain one or more halogen
atoms. The hydrolyzable silane R may have a general formula of
CF.sub.3(CF.sub.2).sub.p(CH.sub.2).sub.qSi(OCH.sub.2CH.sub.3).sub.3
where p is less than about 20 and may about 8 or less and where q
is about 2. Other groups besides (OCH.sub.2CH.sub.3).sub.3, such as
those based on methyl, propyl, or butyl groups, may be substituted
and fall within the new art of this patent when they also are
hydrolyzable. Other halogens, such as chlorine, may be substituted
for the fluorine.
[0037] An example fluoroalkylalkoxysilane is
tridecafluor-1,1,2,2,-tetrahydrooctyltriethoxysilane. An example of
such a silane is Dynasylan F8261 (Degussa Corp.).
[0038] The final coating produced may have a surface free energy
(also referred to as the surface tension) of the coating is less
than about 32 millinewtons/meter and may have a surface free energy
less than about 25 millinewtons/meter and may have a surface free
energy less than about 15 millinewtons/meter and may be less than
about 10 millinewtons/meter.
[0039] The coating formulation may have materials added to modify
its viscosity or surface tension. Examples of such materials are
amorphous silica, such as in powder form. An example amorphous
silica is fumed silica and precipitated silica. An example
amorphous silica is CAB-O-SIL.RTM. HS-5 (Cabot Corporation).
Surfactants may also be added to modify the viscosity or surface
tension of the formulation.
[0040] The coating formulation may include amorphous silica mixed
with a strong base. The amorphous silica-strong base mixture may be
used to augment or replace some or all of a colloidal silicate
material and be mixed with fillers or other materials such as
hydrolyzable silanes.
[0041] FIG. 1 illustrates one embodiment of a method for preparing
coating formulations in accordance with the present invention. As
illustrated, the method of preparation may include the step of
combining a combination of silica, an inorganic filler and a base
in an amount sufficient to cause the combination to have a pH of at
least 10.5 at some point during the preparation process, step 102.
By way of example, the combining step 102 may comprise combining
the constituents in varying orders and may include mixing,
agitating and/or shaking the combination one or multiple times. In
one approach, colloidal silica, at least one inorganic filler and
potassium hydroxide may be combined. In another approach, an
amorphous silica such as fumed silica, and potassium hydroxide may
be initially combined, then colloidal silica and an inorganic
filler may be added thereto. In yet another approach, the base may
even be added later in the process (e.g., at step 106 or step 108,
or between steps 106 and 108 noted below). In each approach, the
base (e.g., potassium hydroxide) functions to effectively dissolve
at least a portion of the silica. As further illustrated in FIG. 1,
the method may optionally include the step of combining an alkoxy
silane into the combination, step 106. As noted above, the
additional of an alkoxy silane serves to enhance the non-stick
properties of the coating formulation.
[0042] As illustrated in FIG. 1, the preparation method may further
include the optional step of combining at least one of water, a
surfactant and a solid into the combination, step 108. As
previously noted, such constituents may be added to enhance the
ability of the formulation to flow or otherwise cover surfaces to
which the formulation may be applied. In relation to the optional
steps, 106 and 108, the illustrated embodiment may also include the
further step of waiting a predetermined time period after such
step(s), step 110, so as to reduce the viscosity of the
combination. In this regard, a waiting period after step 106 may
serve to successively flocculate and peptize the silica. In
relation to step 108, the waiting period may serve to allow for the
hydrolization of silane alkoxy groups (e.g., when water is combined
in step 108). As noted in FIG. 1, after step 102 and optional steps
106-110 have been completed, the prepared formulation may be
utilized to coat an apparatus component such as a metal surface
(e.g., an electrosurgical blade).
[0043] In this regard, reference will now be made to FIG. 2 which
illustrates an exemplary embodiment of a method of coating a
surface of at least one apparatus component with the inventive
formulations (e.g., a metal surface such as an electrosurgical
blade). As shown, the method may include the steps of applying the
coating formulation to the apparatus component surface, step 202,
and drying the applied coating formulation on the apparatus
component surface, step 204. The applying step 202 may be completed
utilizing any of a variety of techniques, including for example,
dipping, spraying, brushing, rolling, printing, etc. Similarly the
drying step 204 may be completed in any manner that may function to
remove liquid from the coating formulation so as to yield a dry
coated apparatus component surface. By way of example, such drying
step may include the sub-step of exposing the coated apparatus
component to a predetermined temperature range sufficient to
vaporize or otherwise remove liquid present in the formulation, and
including an elevated ambient temperature for a predetermined time
period. As noted, the coating step 202 and drying step 204 may be
optionally repeated a number of times to desirably build-up the
coating layer in increments and thereby enhance coverage and
overall performance.
[0044] Following the drying step 204, the method may further
include the step of curing the applied coating formulation on the
apparatus component surface so as to yield a durable, high
temperature surface coating, step 206. Further, depending upon the
constituents used in the formulation, non-stick and other
properties may be realized as otherwise described hereinabove. Of
note, while separate drying and curing steps are shown in FIG. 2,
it should be realized that an extended drying time period will also
serve to cure the inventive formulations. As such, overlap may
occur between the drying and curing stages of the process.
[0045] An example coating formulation, in weight percent, is
TABLE-US-00001 Silica (from colloidal silica) 20-30 Filler 15-30
KOH 8.5-10 Water (from colloidal silica 35-50 and KOH solution)
Fluorinated Silane 0.25-5
[0046] A more specific example formulation is
TABLE-US-00002 Component Mass (gm) % Colloidal silica (Levasil
50/50) 56.2 55.3 Silica/Alumina fiber (RF 20/99) 7.1 7.0
Montmorillonite (Nanomer I.44P) 16.5 16.2 KOH (51 weight percent)
18.8 18.5 Fluorinated Silane (F8261) 2.3 2.3 Fumed silica (HS-5)
0.75 0.74
[0047] For example, the colloidal silica, filler, and KOH solution
are combined and mixed by shaking for one minute. The fluorinated
silane is then added and the mixture shaken 15 minutes. After
shaking, wait 12 hours. During this period the mixture will become
less viscous as the flocculated silica peptizes and the silane
alkoxy groups hydrolyze. Add the fumed silica and shake five
minutes. Wait one hour. The mixture may then be applied by dipping,
spraying brushing, printing, or other means.
[0048] The coating may be applied using any means that conveys a
liquid to the object to which the coating is to be applied. Such
methods include spraying, dipping, brushing, rolling, pad printing
and printing. More than one coat may be applied, such as within 5
seconds and 4 hours of when previous coats were applied or within 5
seconds and 10 minutes of when previous coats were applied.
[0049] The coated article may be allowed to air dry at between
about 60 and 200 degrees Fahrenheit for between about 1 and 8 hours
and then cured at between about 350 and 500 degrees Fahrenheit for
between about 15 minutes and one hour. The final cure temperature
may be between about 400 to 475 degrees Fahrenheit. To reduce
bubble formation during curing the temperature may be ramped
between an air dry temperature and the final cure temperature such
as, for example, over an interval of between about one and eight
hours or over about three to six hours. The final cure may be
immediately after air drying or it may be delayed.
[0050] A coated article may be a substantially organic surface such
as cloth or wood to which the coating is applied and allowed to
dry. For materials that cannot withstand high temperatures a cure
temperature less than the temperature that damages the material may
be used, such as 350 degrees, although longer cure times will be
required than when higher temperatures are used.
[0051] A coated article may be a metal part, such as a component of
an exhaust system, that needs to withstand temperatures exceeding,
for example, 450 degrees Fahrenheit. The coated article may be a
metal surface that benefits from having non-stick or reduced-stick
properties, such as cookware or oven coatings. Such surfaces can be
made from, for example, metal or glass. The coating may be applied
to a glass surface to improve its non-stick properties. Articles
may be coated to provide improved properties during elevated
temperature service including temperatures over 450 degrees
Fahrenheit. The coating may be applied articles expected to
experience temperatures exceeding 600 degrees Fahrenheit, such as
the surfaces near the edges of electrosurgical instruments where
temperatures are believed to exceed 600 degrees Fahrenheit and may
exceed 1,000 degrees Fahrenheit.
[0052] FIG. 3 illustrates the cross section of an electrosurgical
instrument, in this case an electrosurgical blade, that has been at
least partially coated. The preferred thickness of the coating
using the formulation of the present invention is between about
0.001 and 0.1 inches and more preferably between about 0.002 and
0.010 inches. Preferably, at least part of the blade is left
uncoated or with a coating that leads to an impedance less than
about 5,000 ohms so that transfer of electrical energy is
facilitated between the electrosurgical instrument and the tissue,
such as when a very thin edge is exposed through the insulation.
The blade body 1 is surrounded by insulation 2, defined by the
inventive coating except for at least a portion of the peripheral
edge. The length of the body extends into the page in this
figure.
[0053] Various additional embodiments and modifications may be
apparent to those skilled in the art and are within the scope of
the present invention as defined by the claims which follow.
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