Apparatus for detaching surgical blades

An apparatus for detaching a blade from a scalpel handle is provided. The blade has a cutting portion and a heel portion and is removably mounted on a tang of the scalpel handle. The apparatus has a flexible blade detachment member with a stepped portion for engaging the heel of the blade as the handle is withdrawn and a leading angled portion. A backing member is provided with the detachment member being arranged adjacent the backing member so that during use the detachment member flexes in only one direction, away from the mounting tang in response to force applied by the handle to the leading angled portion thereby causing the blade and the handle to be separated and detached relative to each other. Upon withdrawing the tang from the opening, the stepped portion engages the heel of the blade resulting in detachment of the blade from the tang.

TECHNICAL FIELD

The present invention relates generally to apparatus, devices, tools and systems directed to removing, used disposable surgical scalpel blades from scalpel handles and safely disposing of such contaminated blades.

BACKGROUND

Any references to methods, apparatus or documents of the prior art are not to be taken as constituting any evidence or admission that they formed, or form part of the common general knowledge.

It is known that modern surgical scalpel blades are disposable, and are designed to fit a reusable handle to form a surgical knife.FIGS. 1 and 1Aillustrate a commercially available surgical knife50which comprises a reusable handle10and disposable blade20. The surgical blade20comprises a sharpened tip22and cutting edge24at the forward portion of the blade and a shank23extending to the rear portion21of the blade20which forms the heel25of the blade20. The blade20is formed with a central elongate slot26. Shoulders29of the central slot26extend between a wider trailing slot portion27and narrower leading portion39of the slot26act as detents.

The scalpel handle10(shown in part) has an elongated boss, or tang12, that is received into the central elongate slot26of the blade20. The tang12has a region13of reduced thickness, with a forward-facing shoulder14located at the rear portion of the tang12where it attaches to the scalpel handle10. The front19of the tang12is typically rounded, and the shoulder14of the reduced-thickness region is also typically rounded. The tang12comprises a lip16having a relatively greater thickness when compared with the shoulder14and is provided with a groove17extending around the lip16. Whilst,FIGS. 1and2illustrate a specific type of scalpel blade, it is known that scalpel blades can have many other shapes and sizes.

In order to mount a disposable scalpel blade20to handle10, the front end19of the tang12is inserted into the trailing, wider part27of the scalpel blade's elongate slot26and pushed forward so that the narrow portion39of the scalpel blade slot26slides in the tang's grooves17until the rear edge41of the scalpel blade's slot26clears the rear of the lip16of the tang12so that the rear portion21of the scalpel blade20can then flatten, or snap, down against the reduced thickness region13of the tang thereby locking the blade20to the scalpel handle10. In this position the rear heel portion25of the scalpel blade20locates against or close to the shoulder14which thus serves as a blade-retaining projection. The scalpel blade20is held from moving further backwards on the tang12by the detents29of the elongate slot of the blade20which abut the rearward ends of the groove17of tang12.

To remove the scalpel blade20from the scalpel handle's tang12, the heel portion25of the blade20must be brought away from a shoulder portion14of the tang12so that the rear edge41of the enlarged portion27of the slot26clears the lip16so as to permit the handle10to be drawn away from the scalpel blade20. Withdrawing the tang12from the scalpel blade20involves sliding the tang12rearwardly so that its groove17disengages from the narrow portion39of the scalpel blade slot26.

The removal of a scalpel blade20from a scalpel handle10is a problem that needs to be addressed. Whilst specialized blade removal tools and devices are known in the prior art, one of the problems associated with such tools is that the operation of such known tools typically requires a user to use both their hands for removing the blade20from the handle10. For example, U.S. Pat. No. 5,088,173 describes such a two-handed blade removal tool. The use of two hands for blade removal is considered to be generally unsafe and unreliable. Another problem associated with the prior art tools and devices is that these devices typically include several movable parts. For example, a blade removal tool that incorporates a significant number of moving parts is described in US Patent Publication No. 20150047170A1. The inclusion of a high number of movable parts can make manufacturing of the tool difficult. Another type of blade removal tool is described in international patent publication No. WO2004093706A1 however the tool that is described therein is specifically designed to remove only one blade and then not to be used again and so is impractical in many situations. Another tool for the removal of scalpel blades is described in U.S. Pat. No. 5,875,533 however, the tool that is described therein is able to accommodate only a limited range of scalpel blades and handles. Some of the other problems associated with currently known blade detachment devices relate to reliability of the prior art devices and high rates of failure due to excessive friction and jamming. Therefore, in view of the shortcomings it would be desirable to provide a blade removal tool, device or apparatus which addresses some of the problems known in the prior art.

SUMMARY OF THE INVENTION

In one aspect, the invention provides an apparatus for detaching a blade from a scalpel handle, the blade having a cutting portion and a heel portion, said blade being removably mounted on a tang provided on the scalpel handle, said apparatus comprising:a flexible blade detachment member having a stepped portion for engaging the heel of the blade and a leading angled portion; anda backing member;the detachment member being arranged adjacent the backing member such that during use the detachment member flexes in only one direction, away from the mounting tang in response to force applied by the handle to the leading angled portion thereby causing the blade and the handle to be separated and detached relative to each other wherein upon exerting a manual force for withdrawing the tang from the opening, the stepped portion engages the heel of the blade resulting in detachment of the blade from the tang.

In an embodiment, the apparatus further comprises a backing plate arranged for constraining the flexing direction of the detachment member.

In an embodiment, the detachment member defines an opening, preferably in the form of a tang receiving slot. Preferably, the opening extends between a proximal end and a distal end, the opening being provided for receiving the tang therein and positioning the mounted blade adjacent an underside of the detachment member.

In an embodiment, the detachment member further comprises a spacing portion for separating the heel of the blade from a shoulder portion connecting the tang with the handle, the spacing portion being shaped for insertion in between the heel of the blade and the shoulder portion.

In an embodiment, the spacing portion is shaped such that insertion of the tang into the opening results in insertion of the spacing portion in between the blade and the tang.

In an embodiment, the spacing portion is shaped such that gradual insertion of the tang along a length of the opening results in a corresponding increase in the spacing in between the tang and the heel portion of the blade.

In an embodiment, insertion of the tang into opening results in flexing of the spacing portion in a direction away from the tang thereby increasing the spacing between the tang and the heel portion of the blade.

Preferably, gradual insertion of the tang from the proximal end to the distal end of the opening results in positioning of the spacing portion in between the tang and the blade.

In an embodiment, upon insertion of the tang into the opening, at least a part of the scalpel handle is positioned in between the detachment member and the heel of the blade thereby applying a flexing force upon the detachment member resulting in the flexing of the detachment member (which is constrained by the backing member). During use, a flexing force is generated when the shoulder portion presses upon the detachment member, specifically the spacing portion of the detachment member (which is constrained to flex in a downward direction only) resulting in the downward flexing of the spacing portion of the detachment member.

In an embodiment, the spacing portion comprises two mutually opposed surfaces. When the spacing portion is positioned in between the shoulder portion and the heel of the blade, one of said mutually opposed surfaces is adapted for engaging the heel of the blade; and the other of the mutually opposed surfaces is adapted for engaging the shoulder.

In an embodiment, the spacing portion comprises a convergent configuration such that the spacing portion preferably converges generally in a direction towards the proximal end of the opening. Preferably, the spacing portion comprises a triangular cross section.

In an embodiment, the stepped portion is positioned across a length of the detachment member adjacent said spacing portion.

Preferably, the stepped portion is formed integrally with the spacing portion.

In an embodiment, the detachment member further comprises a blade engaging portion, the blade engaging portion preferably formed integrally with the spacing portion such that during use, upon insertion of the tang into the opening, the blade mounted on the tang engages the blade engaging portion.

Preferably, upon exerting a manual force for pulling the tang out of the opening, the blade abuts the blade engaging portion and the stepped portion engages the heel of the blade resulting in detachment of the blade from the tang.

In an embodiment, the apparatus further comprises a collection chamber positioned below the detachment member for collecting the blade when the blade becomes detached from the scalpel handle.

In an embodiment, the apparatus further comprises a guide, preferably arranged adjacent the proximal end of the opening, for guiding the tang into the opening and positioning the mounted blade along an underside of the detachment member.

In an embodiment, the apparatus further comprises a support, preferably positioned adjacent said guide for supporting at least a part of the scalpel handle during insertion of the tang into the opening.

In an embodiment, the blade detachment member and the backing plate are arranged relative to a supporting panel preferably positioned above a collection chamber.

In an embodiment, the apparatus further comprises a cover, preferably arranged relative to the housing, said cover being operable for allowing access to the opening defined by the backing plate.

In an embodiment, the apparatus further comprises a mounting arrangement for mounting the blade detachment member and the backing plate relative to a mounting surface.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring toFIGS. 2 to 7, a first embodiment of the present invention in the form of a blade removal device100is illustrated. The blade removal device100comprises a flexible blade detachment member110(preferably comprising a flexible polymeric material) that is arranged alongside a rigid polymeric backing plate120. Specifically, the backing plate120is contiguously positioned above the flexible blade detachment member110in order to constrain the flexing of the blade detachment member110and only allow downward flexing of the detachment member110during use.

The detachment member110is formed with a longitudinal opening130that extends between a leading end132and a trailing end134. The opening130is wide enough for the tang12to pass through but sufficiently narrow to obstruct passage of the blade20. The opening or slot130is defined by the detachment member110and is shaped for positioning the tang12within the opening130which results in the mounted blade20being positioned adjacent an underside portion of the detachment member110, as best shown inFIGS. 3, 3aand4. The backing plate120is formed with a backing plate slot122that is wider than the detachment member opening130. The backing plate slot122extends about the opening130to accommodate the width of the handle10as the tang12is received in the opening130. The backing plate slot122is sized to receive handles of varying sizes including larger handles. A guiding arrangement170is also provided for guiding the tang12into the opening130. Specifically, spaced apart guiding supports172and174(identified inFIG. 4) are provided for supporting and guiding the tang12into the opening130. As shown particularly clearly inFIGS. 3ato5, the rearwardly diverging sides111a,111bof the shoulder14generate frictional forces against the leading end115of the detachment member110when the handle10is pushed into the opening130at a slight inclination in a downward direction as shown inFIG. 4A.

The detachment member110further comprises a spacing portion112for separating the heel25of the blade20from the tang12. The spacing portion112comprises a substantially triangular or convergent cross section which converges to a leading angled portion in the form of an angular tip115that assists the spacing portion112to become positioned in between the heel25of the blade20and the tang12when the tang12is inserted into the opening130. Therefore, gradual insertion of the tang12into the opening130results in the shoulder14pushing the spacing portion112(which is restrained by the backing plate120) which causes the spacing portion112to flex in a downward direction due to the angular tip115. The flexing of the spacing portion112brings the heel25of the blade20away from the shoulder14which eventually results in the spacing portion112becoming wedged in between the shoulder14and the heel portion25of the blade20as shown inFIG. 4. Referring toFIG. 4ain particular, the force F (item43) used to push in the handle is at a slight incline. The pushing force F (item43) is resolved by the angular tip115into a horizontal component H (item45) (the force that moves the scalpel handle10) and a vertical force V (item47) (which is the force that flexes the spacing portion downward). As explained in the earlier sections, the contiguous arrangement of the backing plate120adjacent the detachment member110ensures that the spacing portion112always flex in one direction.

Further insertion of the tang12into the opening130results in the spacing portion112becoming positioned in between the heel portion25of the blade20and the shoulder14of the scalpel handle10. The positioning of the triangular spacing portion112by the initial insertion or pushing of the tang12into the opening130results in a downward flexing force V47, being applied on the spacing portion112whilst the tang proceeds along the opening130due to horizontal force H45. Any tendency for upward flexing of the spacing portion112is restricted due to contiguous arrangement of the backing plate120as a result of which flexing of the spacing portion112is limited in the downward direction. The flexing of the spacing portion112also results in the heel25of the blade20being brought away from the shoulder portion14and becoming spaced apart from the shoulder14The bringing away of the heel25results in the spacing portion112eventually becoming wedged in between shoulder14and the heel25. The positioning of the backing plate120to constrain or restrict the movement of the detachment member110, specifically the spacing portion112also prevents the tang12and the handle10from inadvertently becoming lodged under the spacing portion112resulting in failure of the blade detachment device100. The flexing of the spacing portion112in a downwardly direction away from the tang12is best illustrated inFIG. 5. It is important to note that the contiguous positioning of the backing plate120constrains the flexing of the spacing portion112in one direction only. Referring particularly toFIG. 5, it is important to note that even though, the heel portion25of the blade20becomes detached from the shoulder14of the tang12, the shank23of the blade20which defines the blade slot remains attached to the tang's grooves in this configuration. It is also important to note that upon being flexed, the spacing portion112extends beyond the plane of the tang12. The attachment of the shank23of the blade20with the tang's grooves in combination with the convergent configuration of the spacing portion112results in the heel portion25becoming positively biased in a direction towards the shoulder14.

Referring toFIG. 6, when the tang12is inserted further so that the tang12is positioned along the entire length of the opening130in a fully inserted position the heel portion25of the blade20slides past the spacing portion112and over a stepped portion114of the detachment member110to become positioned in abutment with the blade engaging portion116. The positive bias on the blade20due to the positioning of the spacing portion112(shown inFIG. 5) provides a pushing force to snap the heel portion25behind the stepped portion114of the detachment member110. Once again, it is important to note that the shank23of the blade20which defines the blade slot remains attached to the tang's grooves17in this configuration shown inFIG. 6.

Upon withdrawal of the tang12from the opening130, a pulling force is also applied upon the blade20which remains attached to tang's grooves17(shank23is attached to the tang's grooves17). However, during the withdrawal of the tang12(which involves manual pulling of the handle10) the blade20also undergoes an initial movement which results in the abutment of the heel25of the blade20with the stepped portion114of detachment member12. Even in the fully inserted position, the shank23of the blade20is partially brought out of the tang's grooves due to lifting of the heel25relative to the shoulder14. The raised profile of the stepped portion114functions as a stop member and prevents the blade20from being withdrawn any further even when manual pulling force is applied upon the tang12by way of a user pulling the handle10out of the opening130. As a result of the abutment of the stepped portion114with the heel portion of the blade20, the tang12is gradually withdrawn out of the blade slot when the manual pulling force continues to be applied by the user. In this configuration, the stepped member114functions as a catcher for catching the blade20when the tang12is withdrawn out of the opening130. Once the blade20becomes completely detached from the tang12, the detached blade20falls into a collection chamber160.

Referring toFIGS. 1, 2 and 7, the collection chamber160may be provided in the form of an open top container comprising a base162and upstanding walls164defining an internal volume of the collection chamber160. The blade removal device100may be positioned substantially above the upstanding walls164of the collection chamber160. As shown inFIGS. 1 and 2, the blade removal device100may be fastened onto a top panel166which may be positioned above the collection chamber160. A hingedly attached cover flap190is also provided for allowing access to the opening130. A mounting arrangement180is also provided for placing the blade removal device10upon a mounting surface. The mounting arrangement180comprises a mounting bracket182defining a cradle for receiving the base162. Outwardly extending projections184in the mounting bracket182are configured for attachment to projection receiving portions186provided along the side walls164for releasably fastening the collection chamber160(and the blade removal device100mounted upon the top panel166) to the mounting bracket182. The blade removal device100shown inFIGS. 2 to 7is positioned or oriented to allow sideways insertion of the tang12into the opening130in a substantially horizontal configuration.

Referring toFIGS. 8 to 14, a second embodiment of the present invention in the form of a blade removal device200is illustrated. The blade removal device200comprises a flexible blade detachment member210(preferably comprising a resilient polymeric material) that is arranged alongside a backing plate220. Specifically, the backing plate220is positioned alongside the flexible blade detachment member210in a substantially parallel arrangement in order to constrain the flexing of the blade detachment member210and only allow downward flexing of the detachment member210during use.

The detachment member210defines an opening230that extends between a proximal end232and a distal end234. The opening230is shaped for receiving the surgical blade50, specifically the tang12of the handle10. The opening or slot230is defined by the detachment member230and is shaped for positioning the tang12within the opening230which results in the mounted blade20being positioned adjacent below the detachment member210, as best shown inFIGS. 10 and 11. A guiding arrangement270is also provided for guiding the tang12into the opening230during use.

Unlike the opening130in the blade removal device100(illustrated inFIGS. 1 to 7), the opening230is generally oriented in a transverse upstanding configuration which allows the blade20, specifically the leading end of the blade20to be inserted into the opening230in a generally downwardly direction.

Referring toFIGS. 11 to 14, the detachment member210further comprises a spacing portion212for separating the heel25of the blade20from the tang12. The spacing portion212comprises a substantially triangular or convergent cross section which allows the spacing portion212to become positioned in between the heel25of the blade20and the shoulder14when the tang12is initially inserted into the opening230. Gradual insertion of the tang12into the opening230results in the shoulder14pushing the spacing portion212(which is restrained by the backing plate120) which causes the spacing portion212to flex in a downward direction. The flexing of the spacing portion212lifts the heel25of the blade20which eventually results in the spacing portion212becoming wedged in between the shoulder14and the heel portion25of the blade20as shown inFIG. 11.

Further insertion of the tang12into the opening230results in the spacing portion212becoming completely positioned in between the heel portion25of the blade20and the and the shoulder14of the scalpel handle10. The positioning of the triangular spacing portion212by the initial insertion or pushing of the tang12into the opening230results in a downward flexing force on the spacing portion212. The upward flexing of the spacing portion212is restricted due to contiguous arrangement of the backing plate220as a result of which flexing of the spacing portion212is limited in the downward direction. The flexing of the spacing portion212also results in the heel25of the blade20lifting away from the shoulder portion14and becoming spaced apart from the shoulder14The lifting of the heel25results in the spacing portion212eventually becoming wedged in between shoulder14and the heel25. The positioning of the backing plate220to constrain or restrict the movement of the detachment member210, specifically the spacing portion212also prevents the tang12and the handle10from inadvertently becoming lodged under the spacing portion212resulting in failure of the blade detachment device200. The flexing of the spacing portion212in an outwardly direction away from the shoulder14and the backing plate220is illustrated inFIG. 12. It is important to note that the positioning of the rigid backing plate220alongside the detachment member110constrains the flexing of the spacing portion212in one direction only. Referring particularly toFIG. 12, it is important to note that even though, the heel portion25of the blade20becomes detached from the shoulder14the shank23of the blade20(which defines a part of the blade slot) remains attached to the tang's grooves in this configuration. It is also important to note that the spacing portion212comprises a slightly raised profile and projects beyond the plane of the tang12as shown inFIG. 12. The attachment of the shank23of the blade20with the tang's grooves in combination with the convergent configuration of the spacing portion212results in the heel portion25becoming positively biased in a direction towards the shoulder14.

Referring toFIG. 13, when the tang12is inserted further into the opening230so that the tang12is positioned along the entire length of the opening230, the heel portion25of the blade20slides past the spacing portion212and over a stepped portion214of the detachment member210to become positioned in abutment with the blade engaging portion216. The positive bias on the blade20due to the positioning of the spacing portion112(shown inFIG. 12) provides a pushing force to snap or push the heel portion25behind the stepped portion214of the detachment member110(as shown inFIG. 13). Once again, it is important to note that the shank23of the blade20which defines the blade slot remains attached to the tang's grooves in this configuration shown inFIG. 13.

Upon withdrawal of the tang12from the opening230, an upwardly directed pulling force is also applied upon the handle10. Specifically, the pulling force is applied upon the tang12and the blade20which remains attached to at least a forward end of the tang's grooves (shank23is attached to the tang's grooves). However, during the withdrawal of the tang12(which involves manual pulling of the handle10) the blade20also undergoes an initial movement which results in the abutment of the heel25of the blade20with the stepped portion214. The raised profile of the stepped portion214functions as a stop member and prevents the blade20from being withdrawn any further even when manual pulling force continues to be applied upon the tang12by way of a user pulling the handle10out of the opening230. As a result of the abutment of the stepped portion214with the heel portion of the blade20, the tang12is gradually withdrawn out of the blade slot of the blade20when the manual pulling force continues to be applied by the user. In this configuration, the stepped member214functions as a catcher for catching the blade20when the tang12is withdrawn out of the opening230. Once the blade20becomes completely detached from the tang12, the detached blade20falls into a collection chamber260below the blade removal device200.

Referring toFIGS. 8, 9 and 14, the collection chamber260may be provided in the form of an open top container comprising a base262and upstanding walls264defining an internal volume of the collection chamber260. The blade removal device200may be positioned on the base262in an upstanding configuration. As shown clearly inFIG. 14, an end portion217of the detachment member210may pivot relative to the base260by way of a pivoting arrangement270.FIG. 14illustrates an elevated in-use configuration of the blade removal device200. The blade removal device200may also be pivoted into a lowered position to stow the device200and place the device200within the confines of the container260during periods of non-use. A hingedly attached cover flap290is also provided for closing the container260when the blade removal device200is in a stowed configuration.

In compliance with the statute, the invention has been described in language more or less specific to structural or methodical features. The term “comprises” and its variations, such as “comprising” and “comprised of” is used throughout in an inclusive sense and not to the exclusion of any additional features. It is to be understood that the invention is not limited to specific features shown or described since the means herein described comprises preferred forms of putting the invention into effect. The invention is, therefore, claimed in any of its forms or modifications within the proper scope of the appended claims appropriately interpreted by those skilled in the art.

Throughout the specification and claims (if present), unless the context requires otherwise, the term “substantially” or “about” will be understood to not be limited to the value for the range qualified by the terms.

Any embodiment of the invention is meant to be illustrative only and is not meant to be limiting to the invention. Therefore, it should be appreciated that various other changes and modifications can be made to any embodiment described without departing from the scope of the invention.

Features, integers, characteristics, or groups described in conjunction with a particular aspect, embodiment or example of the invention are to be understood to be applicable to any other aspect, embodiment or example described herein unless clearly incompatible therewith.