Source: http://www.docstoc.com/docs/40524511/Suture-Needle-And-Its-Manufacturing-Process---Patent-4890614
Timestamp: 2015-05-22 19:25:32
Document Index: 14543505

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Suture Needle And Its Manufacturing Process - Patent 4890614 by Patents-189
OF THEINVENTIONThis invention relates to a suture needle and its manufacturing processes. More particularly, the suture needle is used for medical treatment, in which a suture is previously inserted and fixed within a needle body.DESCRIPTION OF THE PRIOR ARTConventionally, there are known two types of suture needles. According to a first type of suture needle, every time a needle is used, a suture is hooked in an aperture of a needle body. According to a second type, the suture is previously fixedin a hole formed at a front part of the needle body at the manufacturing stage. In the first type, every time the suture needle is used, sterilization is required and the suture may be disengaged from the aperture of the needle body, so that it is anold-fashioned type. Today, the second type is prevailing in advanced countries. That is, it is also a disposable type.[I] FIGS. 8(a) to 8(d) show respective views of a first embodiment of a conventional suture needle which is frequently used today. Numeral 1 is a semicircular needle body made of stainless steel, which comprises a fixing part 2 for fixing asuture 3 at an end of the needle body 1. As shown in 8(d), the fixing part 2 consists of a hole 2a formed in an axial direction of the needle body 1. The suture 3 is inserted into the hole 2a and firmly fixed therein by caulking means.According to a conventional process for manufacturing needles, a stainless steel thin rod is cut off with a suitable length for a needle body. Then, the hole 2a is bored by laser processing, drilling or the like. Subsequently, the suture 3 isinserted into the hole 2a manually and fixed therein by caulking means.The aforesaid prior art has the following disadvantages and inconveniences.(1) The depth of the hole 2a for inserting the suture 3 therein is limited in view of boring operation, so that fixation of the suture in the hole 2a is not always complete. Accordingly, disengagement of the suture from the hole may occureasily. If caul
United States Patent: 4890614
4,890,614
A large number of needle patterns are integrally associated with each other
on an extended U-shaped metal plate. After that, a pointed end of
individual needle patterns is formed, and a series of individual needle
patterns are divided into a plurality of segmented needle bodies. Then, a
suture is inserted into a hollow portion of the needle body. By closing
both walls of the needle body, a suture needle can be produced one after
Kawada; Tsutomu (Tokyo, JP), Nakamura; Yasuo (Nihonbashi Honcho Chuo-Ku, JP)
Nakamura; Yasuo
07/236,274
29058Mar., 1987
830926Feb., 19864672734
606/226  ; 163/1
B21G 1/08&amp;nbsp(20060101); B21G 1/00&amp;nbsp(20060101); A61B 17/06&amp;nbsp(20060101); A61B 017/06&amp;nbsp()
128/339,335.5 163/1,5 223/102
1984, Johnson and Johnson Vis-Black Surgical Needle..
This is a continuation of application Ser. No. 029,058 filed Mar. 23, 1987,
abandoned, which in turn is a continuation application of Ser. No. 830,926
filed Feb. 19, 1986, now U.S. Pat. No. 4,672,734.
1.  A suture needle structure comprising a suture and curved metal needle body in which the needle body has a hollowed portion extending from a back end of the needle body
toward a point front end of the needle body over substantially the entire length of the needle body, said suture extending into and along substantially the entire length of the hollow portion and the suture being caulked in the hollow portion, the needle
body comprising a plate surrounding the suture with opposite lengthwise edges of the plate being in contact substantially along the entire length of the needle body.  Description
This invention relates to a suture needle and its manufacturing processes.  More particularly, the suture needle is used for medical treatment, in which a suture is previously inserted and fixed within a needle body.
Conventionally, there are known two types of suture needles.  According to a first type of suture needle, every time a needle is used, a suture is hooked in an aperture of a needle body.  According to a second type, the suture is previously fixed
in a hole formed at a front part of the needle body at the manufacturing stage.  In the first type, every time the suture needle is used, sterilization is required and the suture may be disengaged from the aperture of the needle body, so that it is an
old-fashioned type.  Today, the second type is prevailing in advanced countries.  That is, it is also a disposable type.
[I] FIGS. 8(a) to 8(d) show respective views of a first embodiment of a conventional suture needle which is frequently used today.  Numeral 1 is a semicircular needle body made of stainless steel, which comprises a fixing part 2 for fixing a
suture 3 at an end of the needle body 1.  As shown in 8(d), the fixing part 2 consists of a hole 2a formed in an axial direction of the needle body 1.  The suture 3 is inserted into the hole 2a and firmly fixed therein by caulking means.
According to a conventional process for manufacturing needles, a stainless steel thin rod is cut off with a suitable length for a needle body.  Then, the hole 2a is bored by laser processing, drilling or the like.  Subsequently, the suture 3 is
inserted into the hole 2a manually and fixed therein by caulking means.
(1) The depth of the hole 2a for inserting the suture 3 therein is limited in view of boring operation, so that fixation of the suture in the hole 2a is not always complete.  Accordingly, disengagement of the suture from the hole may occur
easily.  If caulking stress is too strong, the needle body 1 may be broken or deformed.
(3) Since the needle body except for the hole portion is of a solid construction, its resilience is relatively low.  Accordingly, there grows the danger that a pointed end of the needle body may be broken and retain in a body during sewing
operation.  Such accident may cause a serious condition.
(4) After the hole has been bored and the suture has been fixed therein, it is no more possible to clean the interior of the hole.  Accordingly, it is impossible to wipe away any foreign matter that may remain in the hole during boring operation.
(6) The boring operation including laser processing, drilling or the like requires high accuracy, so that it is a cumbersome work.  It is very difficult to obtain a bore of a very accurate diameter effective to insert the suture thereinto.
(7) It is also a very cumbersome work even for skilled workers to insert and fix a soft and thin suture into such a minute hole.  The daily output of such conventional suture needles is so limited that the production cost is expensive and quality
is not always uniform.
As shown in FIG. 10(b), the hole means B2 comprises a hole B2a for engaging with a suture, pair of lugs B2b and a recess B2c thereupon.  The pair of lugs B2b are contacted with each other at their upper ends and formed integrally at their lower
end.  Such structure is suitable for inserting the suture therein.
(2) When such suture needle units are produced continuously, they must be lined up correctly and then necessary mechanical processings must be provided.  Accordingly, the production cost is high.
(1) A suture needle body is of a tubular construction.  Namely, a hollow portion is formed in a substantially overall length of the needle body, and a suture is inserted and fixed in the hollow portion.
(h) providing said sature needle with a sterilization treatment.  Other features and advantages of the invention will be apparent from the following description taken in connection with the accompanying drawings.
The hollow portion 11a is made of a U-shaped metal plate M as shown in FIG. 4.  Thus, the hollow portion 11a is formed in a substantially overall length of the needle body 11.  After the suture 13 has been inserted in the hollow portion 11a as
shown in FIG. 2, both sides of the U-shaped metal plate M are caulked hermetically by a suitable press means.  The section of the caulked needle body 11 is circular in this embodiment, but may be triangular or other shape.
The metal plate M made of a stainless steel (in this embodiment) may be formed from a flattened plate or may be an existing U-shaped pipe.  Or, a material of the suture needle body may be made by cutting a round pipe in a semicircular section
form in an axial direction.
(B) Following this step, a nearly triangular cutaway portion C is formed on both walls M1 and M2 of the U-shaped metal plate M as shown in FIG. 5(b).  It is formed with an equal space in a longitudinal direction of the metal plate M in order to
produce a front part 11b of individual suture needle body 11.
(C) Next to this step, the front part 11b is closed as shown in FIG. 5(d), thereby a pointed end 11c is formed.  The section of the pointed end 11c may be circular or triangular, and the pointed end 11c is formed by press means.
(D) Next to this step, a series of the needle patterns 110 combined with each other at respective pointed ends 11c are segmented individually.  A main body 11d of each needle pattern 110 excluding the pointed end 11c is of a U-shaped section as
shown in FIGS. 5(d) and 6(a) to 6(c).
(F) Next to this step, the suture 13 having a suitable length is inserted in a U-shaped overall groove (or the main body 11d) of the needle pattern 110 as shown in FIGS. 6(b) and 6(c).  The U-shaped groove is still open.
(G) Next to this step, both sides of the U-shaped needle pattern 110 are caulked hermetically by press means and the suture 13 is fixed firmly in the main body 11d, namely in the hollow portion having a circular section.  Namely, the needle body
is of a hollow construction extending from its pointed end to its rear end, and the suture is inserted and fixed in a substantially overall length of the needle body.
(1) Since a suture is inserted and fixed within a needle body throughout its substantially overall length, disengagement of the suture from the needle body is entirely prevented.  Such a suture needle may be called an eyeless needle.
(2) Since the needle body is provided with a groove, it is of a tubular structure and becomes lightweight.  In addition, its rigidity is enhanced.
(3) Since a suture is extended through a substantially overall length of the needle body and fixed therein, even if the needle body will locally be broken within a human body, its broken part cannot be remained in it.  Because the whole of the
needle body is supported by the suture.
(5) Because of the absence of the hole structure, any cumbersome work has been removed.  The products of uniform quality can be manufactured at a low cost.
(1) A large number of suture needles can be manufactured in a mass production system.  Accordingly, productivity is very high.
(2) Since no manual operation is required in each production stage, quality of the products is constantly uniform.  Thus, this invention can satisfy a demand for high reliability in medical instruments.
(3) Since a desired number of suture needles are formed from an elongated and flattened metal plate by means of punch press, cutting, bending or the like, a desired diameter of the needle body as well as a desired sectional profile may be
predetermined optionally.  In addition, the production cost is inexpensive.
A second embodiment of the invention will be described with reference to FIGS. 11 to 15(c).  According to this embodiment, a large number of suture needles can be produced successively by press means.
In FIG. 11 there is shown a metal plate M made of a stainless steel.  The metal plate M is produced by the following steps.
(B) Following the above step, each needle pattern 111 is compressed a few times by press means in order to increase its rigidity.  As shown in FIGS. 12(a) to 12(d), the section of the needle pattern 111 is transformed a few times from a
rectangular shape to a round shape and from the round one to the rectangular one.  Finally, the round section of it is obtained as shown in FIG. 13(a).
(G) Subsequently, the large number of needle patterns 111 joined each other to the metal plate M are divided into individual segments.  Then, each segment is bent in a suitable form, and a finished suture needle 141 is obtained.  It is a solid
type suture needle having an opening for inserting a suture.  It is called an eye needle.
According to the second embodiment of the invention, a large number of suture needles can be produced continuously by mechanical means, so that the production cost is low and the quality of each needle unit is uniform and stable.  In addition,
its resilience is very strong.
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