“Study of Bending a Microsurgical Ophthalmic Knife Made of SS304 Wire”

Abstract

The present invention relates to a semi-automatic electro-thermal bending machine designed for the precise bending of microsurgical ophthalmic knives made from stainless steel. This innovative machine utilizes controlled electrical resistance heating to soften the knife material, allowing for accurate shaping and curvature required for various ophthalmic surgical procedures. The apparatus features a variable transformer that adjusts the output voltage based on the knife diameter, ensuring optimal bending conditions. By automating the bending process, the invention reduces human error, increases production efficiency, and enhances the consistency and quality of surgical instruments. Ultimately, this electro-thermal bending machine significantly advances the manufacturing of ophthalmic surgical knives, improving their reliability and performance in delicate eye surgeries.

Specification

Description:

Field of the invention:
[001] The field of invention pertains to the design and development of specialized equipment for the manufacturing of microsurgical ophthalmic knives, specifically focusing on the electro-thermal bending of stainless-steel surgical blades. This innovation addresses the challenges associated with achieving precise angles and curvatures necessary for various ophthalmic procedures, such as cataract surgery and corneal transplantation. By utilizing a semi-automatic bending machine, this invention enhances the precision and efficiency of producing ophthalmic surgical knives, ensuring that they meet the stringent requirements of eye surgeries. The integration of electrical resistance heating technology facilitates the safe manipulation of delicate materials, minimizing the risk of damage during the bending process and contributing to the overall safety and effectiveness of ophthalmic surgical instruments.
Background of the invention and related prior Art:
[002] The background of this invention lies in the critical need for precision and reliability in the manufacturing of microsurgical ophthalmic knives used in delicate eye surgeries. Traditionally, the manual bending of these knives is labour-intensive and prone to errors, often resulting in inconsistencies that can compromise surgical outcomes. Stainless steel, a commonly used material for these instruments due to its durability and biocompatibility, presents unique challenges during the bending process, as improper handling can lead to damage or deformation. Existing techniques do not adequately address the need for consistent and accurate angles, especially for curved blades. This invention introduces a semi-automatic electro-thermal bending machine designed to address these limitations by allowing for precise control over the bending process, utilizing controlled electrical heating to soften the metal. By automating this procedure, the invention enhances production efficiency, reduces human error, and ultimately improves the quality and performance of ophthalmic surgical instruments, aligning with the advancements in modern medical practices.
[003] A patent document RU2341235C1 discloses microsurgical instrument for fragmentation of cataractous lens kernels in a vertical plane contains a handle and a working part which are bridged under an angle of 105°. The working part is executed in the form of a metal plate with width of 0.2-0.3 mm, thickness of 0.15 mm and length of 1.75; 2.0 and 2.25 mm. The left edge of the plate and an end of the cutting part are blunted and cut under an angle of 20°.
[004] Another patent AU2007353372B2 discloses a quick release filter assembly for a pneumatic module of a surgical machine includes a housing, an input port, an output port, a filter, and a flange. The housing has first and second sides, a top, and a bottom. The input port is located on the first side of the housing and is configured to permit gas to enter the housing. The output port is located on the second side of the housing and is configured to permit gas to exit the housing. The filter is located in the housing between the input port and the output port. The flange is rigidly connected to the housing along a periphery of the top of the housing. The flange extends outward along a plane generally parallel with the top of the housing. The flange has a mechanism for connecting the housing to a mounting portion of the pneumatic module. When the mechanism is disengaged, the filter assembly can be removed from the pneumatic module.
[005] A document US20070244496A1 discloses a surgical device for cutting substantially across a cornea of an eye of a patient, the device including a positioning ring to be attached to an eye surrounding a cornea to be cut, and defining an aperture sized to receive and expose the cornea to be cut. The surgical device further includes a cutting head assembly structured to be guided and driven over an upper surface of the positioning ring in a generally arcuate path, and having a cutting element positioned therein and structured to oscillate laterally to facilitate smooth and effective cutting of the cornea. The cutting head assembly is structured to be detachably coupled to the positioning ring by a coupling member which permits movement of the cutting head assembly relative to the positioning ring along the generally arcuate path, but maintains sufficient engagement therebetween to ensure that smooth, steady, driven movement is maintained.
[006] Another document CN113101047B relates to ophthalmic scalpels and methods of use thereof for treating a variety of conditions including ocular disorders such as glaucoma using minimally invasive surgical techniques. The present invention relates to a multi-blade device for cutting intraocular tissue such as Trabecular Meshwork (TM).
[007] A patent document US6503262B1 discloses a retractable micro-surgical tool includes a shell, slidable insert, slide button, spring, and blade. The shell is preferably a hollow tube. A first slot is formed through the wall of the shell at substantially a first end thereof. A second slot is formed through the wall of the shell at substantially a middle of the shell length. A connecting slot is formed between the first and second slots to enable the slide button to be slid therebetween. The slidable insert includes a body, a first cantilever arm, and a second cantilever arm. The blade is preferably inserted into a first end of the body. An end of the blade may have different shapes suitable for performing micro-surgery. The first cantilever arm extends from substantially a middle of said body and the second cantilever arm extends from an end of the first cantilever arm. The slide button is attached to a top of the second cantilever arm at assembly. At least one side of the body has a groove formed therein to provide clearance for the spring. A hole is formed through a middle of the body for attachment of one end of the spring. An end plug is inserted into a second end of the shell for attachment of the other end of the spring.
[008] None of these above patents, however alone or in combination, disclose the present invention. The invention consists of certain novel features and a combination of parts hereinafter fully described, illustrated in the accompanying drawings, and particularly pointed out in the appended claims, it being understood that various changes in the details may be made without departing from the spirit, or sacrificing any of the advantages of the present invention.
Summary of the Invention:
[009] This invention presents a semi-automatic electro-thermal bending machine specifically designed for the precise bending of microsurgical ophthalmic knives made from stainless steel. The machine utilizes controlled electrical heating to soften the knife material, allowing for accurate shaping and curvature to meet the requirements of various eye surgeries. By integrating a variable transformer to adjust the voltage and current settings based on the diameter of the knife wire, the invention ensures optimal bending conditions for different blade specifications. This innovative approach automates the bending process, significantly reducing human error and enhancing production efficiency. Ultimately, the invention contributes to the consistent manufacturing of high-quality ophthalmic surgical instruments, improving their reliability and performance in delicate surgical procedures.
Detailed Description of the Invention with Accompanying Drawings:
[010] For the purpose of facilitating an understanding of the invention, there is illustrated in the accompanying drawing a preferred embodiment thereof, from an inspection of which, when considered in connection with the following description, the invention, its preparation, and many of its advantages should be readily understood and appreciated.
[011] The principal object of the invention is to develop study of bending a microsurgical ophthalmic knife made of SS304 wire. The invention is a semi-automatic electro-thermal bending machine specifically engineered for the precise bending of microsurgical ophthalmic knives, typically constructed from stainless steel. This machine addresses the challenges associated with manually bending surgical knives, which often leads to inconsistencies and potential damage to the delicate instruments. Here's a detailed description of the invention:
1. Design and Structure
The bending machine is designed to accommodate various diameters of ophthalmic knife wires, ensuring versatility in its application. The machine's construction includes:
- Frame and Support: A sturdy framework that securely holds the knife during the bending process, minimizing movement and enhancing precision.
- Electrode Fixtures: Two electrodes that grip the knife wire, ensuring stable contact and alignment for effective heating and bending.
2. Heating Mechanism
At the core of the invention is the electro-thermal heating mechanism, which employs Joule heating to soften the metal:
- Variable Transformer (Variac): This component allows the operator to adjust the output voltage between 3-12 volts. The transformer converts the standard 220V AC input to the desired lower voltage, crucial for controlling the heating process.
- Electrical Resistance Heating: As electrical current passes through the knife wire, resistance generates localized heat, softening the metal at specific points. This heat makes the stainless steel more malleable, facilitating controlled bending.
3. Control System
- Voltmeter: Integrated into the machine, the voltmeter monitors the voltage output in real-time, enabling the operator to maintain optimal bending conditions.
- On/Off Toggle Switch: A simple control mechanism for starting and stopping the machine, ensuring user safety during operation.
4. Bending Process
The bending process follows these steps:
1. Selection of Knife: The operator selects a straight ophthalmic knife of the desired diameter.
2. Power Activation: The machine is powered on, and the knife is securely fixed between the electrodes.
3. Setting Voltage: The operator sets the required voltage using the variac based on the knife's diameter. The invention supports different wire diameters-0.63 mm, 0.84 mm, 1.0 mm, and 1.6 mm-each requiring specific voltages for effective bending (e.g., 3.4V for 0.63 mm, 12.5V for 1.6 mm).
4. Heating Phase: The electric current is activated, and localized heating occurs, softening the metal wire at the designated point.
5. Mechanical Bending: The operator applies mechanical force through the machine's handle, bending the softened metal into the desired curvature while monitoring the angle using an angle protector.
6. Cooling and Inspection: After achieving the desired bend, the current is turned off, and the knife is removed for inspection to ensure it meets the required specifications.
5. Outcome and Benefits
[012] This invention provides a consistent and efficient method for manufacturing ophthalmic surgical knives, ensuring that each instrument is precisely shaped according to surgical requirements. The automation of the bending process not only reduces human error but also increases production speed and capacity, making it a significant advancement in the field of medical instrument manufacturing. Additionally, the machine enhances the safety and effectiveness of surgical procedures by ensuring the reliability and quality of the tools used in delicate eye surgeries.
This invention represents a significant step forward in the manufacturing of microsurgical ophthalmic knives, bridging the gap between engineering innovation and medical precision.
Table1: Required wire diameter for different types of ophthalmic surgical knife
Si No. Ophthalmic Surgical Knife Name Required Wire Diameter
01 Side port lance tip knife 0.63 mm
02 Crescent knife 0.84 mm
03 Keratome point tip knife 0.84 mm
04 Keratome clear cornea knife 0.84 mm
05 MVR knife 1.00 mm
06 Keratome blunt tip knife 1.60 mm





Table2: Experimental outcome for bending ophthalmic surgical knife
Si No. Pressure Required Angle Wire Diameter Output Voltage
01 100 N 45 degrees 0.63 mm 3.4 V
02 100 N 45 degrees 0.84 mm 4.9 V
03 100 N 45 degrees 1.0 mm 6.3 V
04 100 N 45 degrees 1.6 mm 12.5 V

Figure 1. Difference between straight and 45 degree curved ophthalmic surgical knife according to the embodiment of the present invention.
Figure 2. Ophthalmic surgical knife bending machine CAD view according to the embodiment of the present invention.
Figure 3. Flow chart of micro surgical ophthalmic knife bending process according to the embodiment of the present invention.
Figure 4. Ophthalmic surgical knife holding in bending machine according to the embodiment of the present invention.
Figure 5. Ophthalmic surgical knife is bent after the force applied to the machine handle according to the embodiment of the present invention.
Figure 6. Output voltage vs wire diameter line chart according to the embodiment of the present invention.
Figure 7. Ophthalmic surgical blade angle is completely bent at 45-degree angle according to the embodiment of the present invention.
[012] Without further elaboration, the foregoing will so fully illustrate my invention, that others may, by applying current of future knowledge, readily adapt the same for use under various conditions of service. It should also be realized by those skilled in the art that such equivalent constructions do not depart from the spirit and scope of the invention.
Advantages over the prior art
[013] Study of bending a microsurgical ophthalmic knife made of SS304 wire proposed by the present invention has the following advantages over the prior art:
1. Precision and Accuracy: The machine allows for precise bending of surgical knives to specific angles and curvatures, ensuring that each instrument meets the stringent requirements of various ophthalmic procedures.
2. Reduced Human Error: By automating the bending process, the machine minimizes the potential for human error associated with manual bending, leading to more consistent and reliable outcomes.
3. Efficiency and Speed: The semi-automatic design accelerates the production process, allowing for quicker turnaround times in the manufacturing of surgical knives, thus meeting the growing demand in the medical field.
4. Versatility: The machine can accommodate various diameters of ophthalmic knife wires, making it adaptable to different surgical requirements and enhancing its utility in medical instrument production.
5. Material Integrity: The electro-thermal heating process softens the metal without compromising its structural integrity, allowing for the safe manipulation of delicate stainless-steel blades without causing damage.
6. Customization: Surgeons can specify unique angles and curvatures for surgical knives, allowing for tailored instruments that enhance surgical effectiveness and patient outcomes.
7. Improved Safety: By ensuring precise shapes and reducing the risk of instrument failure, the invention contributes to safer surgical procedures and better overall patient care.
8. Cost-Effectiveness: Streamlining the manufacturing process and reducing the need for skilled manual labor can lead to lower production costs and increased profitability for manufacturers.
9. Enhanced Quality Control: The integration of monitoring tools, such as voltmeters, ensures that the bending process adheres to required specifications, facilitating improved quality control in the production of surgical instruments.
10. Bridging Engineering and Medicine: This invention exemplifies the integration of engineering innovation into medical practices, improving the design and function of surgical instruments, ultimately advancing the field of ophthalmology.
[014] In the preceding specification, the invention has been described with reference to specific exemplary embodiments thereof. It will be evident that various modifications and changes may be made thereunto without departing from the broader spirit and scope of the invention as set forth in the claims that follow. The specification and drawings are accordingly to be regarded in an illustrative rather than restrictive sense. Therefore, the aim in the appended claims is to cover all such changes and modifications as fall within the true spirit and scope of the invention. The matter set forth in the foregoing description and accompanying drawings is offered by way of illustration only and not as a limitation. The actual scope of the invention is intended to be defined in the following claims when viewed in their proper perspective based on the prior art.
, Claims:We claim:
1. Study of bending a microsurgical ophthalmic knife made of SS304 wire which consists of:
- a frame configured to securely hold a surgical knife;
- a pair of electrodes positioned to grip the surgical knife wire;
- a variable transformer capable of adjusting the output voltage between 3-12 volts;
- a heating mechanism configured to pass an electric current through the surgical knife wire, generating localized heating to soften the wire;
- a control system including a voltmeter for monitoring the output voltage; and
- a mechanical bending mechanism that applies force to the softened wire to achieve a desired curvature.
2. Study of bending a microsurgical ophthalmic knife made of SS304 wire as claimed in claim 1 wherein the frame includes adjustable components to accommodate surgical knives of varying diameters.
3. Study of bending a microsurgical ophthalmic knife made of SS304 wire as claimed in claim 1 wherein the heating mechanism utilizes Joule heating to induce localized softening along the length of the surgical knife wire.
4. A method for bending microsurgical ophthalmic knives using the semi-automatic electro-thermal bending machine of Claim 1, comprising the steps of:
- selecting a straight surgical knife made of stainless steel;
- securely fixing the surgical knife wire between the electrodes;
- adjusting the output voltage via the variable transformer based on the diameter of the surgical knife wire;
- activating the electric current to induce heating in the surgical knife wire;
- applying mechanical force to bend the softened wire to a desired angle; and
- removing the surgical knife for inspection of the achieved curvature.
5. Study of bending a microsurgical ophthalmic knife made of SS304 wire as claimed in claim 1 wherein the variable transformer is configured to provide a range of output voltages specifically tailored for different diameters of surgical knife wires.
6. Study of bending a microsurgical ophthalmic knife made of SS304 wire as claimed in claim 1 wherein further comprising an on/off toggle switch to control the flow of electrical current to the machine.
7. Study of bending a microsurgical ophthalmic knife made of SS304 wire as claimed in claim 1 wherein the electrodes are designed to ensure stable contact and alignment of the surgical knife wire during the bending process.
8. The method of Claim 4, further comprising the step of monitoring the angle of the bent surgical knife using an angle protector to ensure the desired specifications are met.
9. The method of Claim 4, wherein the mechanical force is applied through a handle connected to the bending mechanism of the machine.
10. Study of bending a microsurgical ophthalmic knife made of SS304 wire as claimed in claim 1 wherein the heating mechanism allows for selective heating of different sections of the surgical knife wire to achieve complex curvatures.

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