JP5548065B2 - Molding method of medical blade - Google Patents

Description

  The present invention relates to a method for forming a medical blade.

For example, a small blade having a sharp cutting edge is used as a medical blade such as a scalpel or a knife used to cut a body tissue such as the skin, an organ, or the cornea. As the shape of the cutting edge of the medical blade or the cutting edge portion including the cutting edge, those having various shapes depending on the incision site and the incision method are known. Also, such medical blades are often disposable after use in order to prevent infection.
Therefore, conventionally, it has been proposed to manufacture a medical blade using press working or casting.
For example, as an example of a medical blade manufactured using press working, Patent Document 1 discloses a round bar-shaped shank made of austenitic stainless steel, a blade portion formed continuously with the shank, and a blade. The medical knife which has the cutting blade formed in the predetermined site | part of the part is described. However, this medical knife forms a cutting blade by pressing a drawn bar material using a convex mold to form an intermediate material, and then grinding and polishing the intermediate material.
Moreover, as an example of the manufacturing method of the medical knife using casting, it is a manufacturing method of the cutting tool used as a knife and a knife in patent document 2, Comprising: Making a blank from a bulk-like amorphous alloy, A method is described for manufacturing a cutting tool that includes forming the blank to form a blade portion and a body portion and sharpening the blade portion to form a sharpened cutting edge.

Japanese Patent Laid-Open No. 9-276284 JP-T-2005-506116

However, the conventional method for forming a medical blade as described above has the following problems.
When using press work as in the technique described in Patent Document 1, it is not possible to form a sharp cutting edge required for a medical knife with about two presses. For this reason, after forming the rough shape of the cutting edge, grinding and polishing are required. Since the cutting edge portion of a medical blade is small and often has a complicated shape, depending on the shape, there is a problem that it takes time for grinding and polishing and cannot be manufactured at low cost.
Further, as in the technique described in Patent Document 2, even when casting is performed using a molten metal of an amorphous alloy, it is necessary to sharpen the blade portion after forming a blank to create a cutting edge. For this reason, depending on the shape, there is a problem that it takes time for grinding and polishing and cannot be manufactured at low cost.
In the case of casting, for example, an amorphous alloy has a small molding shrinkage ratio and is excellent in mold transferability. Therefore, it is possible to form the cutting edge portion by forming the cutting edge portion on the mold, In order to form a highly accurate molding surface on the mold, the cutting edge is formed by the molding surfaces of a pair of molds facing each other, and the cutting blade is formed at the position of the mold dividing surface where these molding surfaces abut each other. There is a need to.
However, in such a mold configuration, a molten metal material enters the mold dividing surface and burrs are generated on the cutting edge. In particular, an amorphous alloy with good mold transferability has a problem that a large amount of burrs are likely to occur, and the toughness of the burrs is high, so that it takes much time to remove the burrs.
For this reason, there is a strong demand for a method for forming a medical blade capable of forming the shape of the cutting edge without performing grinding or polishing after forming.

  The present invention has been made in view of the above problems, and a method for forming a medical blade capable of forming a cutting blade without subjecting the cutting edge portion to secondary processing such as grinding or polishing. The purpose is to provide.

In order to solve the above problems, a method for forming a medical blade of the present invention is a method for forming a medical blade using a mold having a cavity for forming a medical blade having a cutting edge portion, cutting edge to the first die member is at least one of the mold members forming part of the cavity, by placing a metal foil laminate obtained by laminating a plurality of metal foil, forming the shape of the cutting edge A first mold assembling step for forming a part molding surface and assembling the mold subassembly, and the metal foil laminate for the subassembly assembled in the first mold assembling step. A second mold assembling step of assembling the mold having the cavity by attaching a second mold member which is another mold member so as to press the metal foil laminate with a gap therebetween, The mold of the mold assembled in the second mold assembling step. And a molding step for molding by injecting molten metal material into the tee, in the second mold assembly step, the metal foil by being pressed when mounting the second die member laminate is deformed, the said metal foil laminate first mold member, and the metal foil laminate and the second mold member, and a method each metal foil you contact of the metal foil laminate To do.

  Further, in the method for molding a medical blade of the present invention, the first mold assembling step forms the blade edge forming surface, and therefore the metal foil laminate is disposed after the metal foil laminate is disposed. It is preferable to further have a smoothing step of pressurizing and smoothing the end of each layer of the metal foil to be configured.

  In the method for molding a medical blade according to the present invention, the metal material injected into the cavity in the molding step becomes amorphous by cooling at a cooling rate equal to or higher than a critical cooling rate of the metal material. A material is preferred.

  In the method for molding a medical blade of the present invention, any mold member constituting the mold is formed with a gripping member placement portion for placing a gripping member serving as a gripping portion for the medical blade. A gripping member that disposes the gripping member on the gripping member disposition portion of the mold assembled in the second mold assembling step between the second mold assembling step and the molding step. An arrangement step, wherein the metal material is injected along the surface of the holding member arranged in the holding member arrangement step, so that the metal material is formed integrally with the holding member. It is preferable.

  In the method for molding a medical blade of the present invention, it is preferable that the gripping member is provided with a concave hole portion into which the metal material injected in the molding step flows and is filled with the metal material. .

  Further, in the method for molding a medical blade having a recessed hole portion according to the present invention, the recessed hole portion forms an acute angle with respect to the flow path of the metal material along the surface of the gripping member, and the metal material It is preferable to have a shape that branches from the upstream side to the downstream side in the injection direction.

  Further, in the method for molding a medical blade of the present invention, the metal foil laminated in the first mold assembling step is made of a material having a higher thermal conductivity as it approaches a layer forming the cutting edge of the blade edge part. It is preferable that metal foil is laminated.

  In the method for molding a medical blade according to the present invention, a plurality of the subassemblies are assembled in the first mold assembling process, and the first mold assembling process is performed in the second mold assembling process. At least one set of the subassemblies assembled in the above is attached so that the metal foil laminates of the subassemblies are in close contact with each other in the laminating direction, and the cutting edge forming surfaces of the metal foil laminates It is preferable that the shape of the blade edge portion is formed.

  According to the method for forming a medical blade of the present invention, since the forming process is performed using a metal mold having a cutting edge portion forming surface formed of a metal foil laminate, the cutting edge portion is subjected to secondary processing such as grinding or polishing. There exists an effect that a cutting blade can be formed, without giving.

It is the typical top view which shows an example of the medical knife shape | molded by the shaping | molding method of the medical blade tool which concerns on the 1st Embodiment of this invention, its AA sectional drawing, and a left view. It is a perspective view which shows the shape of the B section in FIG. It is typical sectional drawing of the center part of the metal mold | die used for the shaping | molding method of the medical blade of the 1st Embodiment of this invention, and the enlarged view of the C section. It is a typical exploded perspective view of the lower metallic mold used for the molding method of the medical knife concerning a 1st embodiment of the present invention. It is a typical disassembled perspective view of the upper metal mold | die used for the shaping | molding method of the medical blade which concerns on the 1st Embodiment of this invention. It is process explanatory drawing which shows the mode of the shaping | molding process of the shaping | molding method of the medical blade which concerns on the 1st Embodiment of this invention. It is process explanatory drawing explaining the smoothing process of the modification (1st modification) of the shaping | molding method of the medical blade which concerns on the 1st Embodiment of this invention. It is typical sectional drawing which shows the structure of the principal part of the metal mold | die used for the modification (1st modification) of the shaping | molding method of the medical blade which concerns on the 1st Embodiment of this invention. It is the DD sectional drawing in a typical front view, back view, and front view which shows an example of the medical knife shape | molded by the shaping | molding method of the medical blade which concerns on the 2nd Embodiment of this invention. It is a typical front view which shows the holding member of the medical blade which concerns on the 2nd Embodiment of this invention. It is the typical front view of the metal mold | die used for the shaping | molding method of the medical blade of the 2nd Embodiment of this invention, a back view, a left view, and a right view. It is the EE sectional view in Drawing 11 (a), its FF sectional view, and the elements on larger scale of G section. It is the typical right view and front view which show the state which has arrange | positioned the holding member to the metal mold | die used for the shaping | molding method of the medical blade of the 2nd Embodiment of this invention. It is process explanatory drawing in the HH cross section in FIG. 13 which shows the shaping | molding process in the shaping | molding method of the medical blade of the 2nd Embodiment of this invention.

  Embodiments of the present invention will be described below with reference to the accompanying drawings. In all the drawings, even if the embodiments are different, the same or corresponding members are denoted by the same reference numerals, and common description is omitted.

[First Embodiment]
A method for forming a medical blade according to the first embodiment of the present invention will be described.
FIG. 1A is a schematic plan view showing an example of a medical blade formed by the method for forming a medical blade according to the first embodiment of the present invention. FIG.1 (b) is AA sectional drawing in Fig.1 (a). FIG.1 (c) is a typical left view which shows an example of the medical blade shape | molded by the shaping | molding method of the medical blade tool which concerns on the 1st Embodiment of this invention. FIG. 2 is a perspective view showing the shape of part B in FIG. Fig.3 (a) is typical sectional drawing of the center part of the metal mold | die used for the shaping | molding method of the medical blade of the 1st Embodiment of this invention. FIG.3 (b) is an enlarged view of the C section in Fig.3 (a). FIG. 4 is a schematic exploded perspective view of a lower mold used in the method for forming a medical knife according to the first embodiment of the present invention. FIG. 5 is a schematic exploded perspective view of an upper mold used in the method for forming a medical knife according to the first embodiment of the present invention. 6 (a) and 6 (b) are process explanatory views showing the state of the forming process of the method for forming a medical knife according to the first embodiment of the present invention.

First, referring to FIGS. 1A, 1B, 1C, and 2, an ophthalmic knife 1 that is an example of a medical knife formed by the method for forming a medical knife of this embodiment will be described. To do.
The ophthalmic scalpel 1 is used for, for example, a small corneal incision application or a scleral one-surface incision application, and includes a blade portion 1A and a support end portion 1B from the distal end side (the left side in FIG. 1A).
The schematic shape of the blade portion 1A is curved in a thin spherical shell shape having a curvature substantially similar to the curvature of the cornea, and has a substantially fan shape in which the shape in plan view is narrowed from the distal end side to the proximal end side.
The schematic shape of the support end 1B extends from the base end side of the blade 1A so as to be detachably attached to a handle (gripping member) (not shown), and has a plate shape elongated in the extending direction in plan view. .
In the present embodiment, as an example, a constant value t is adopted as the plate thickness of the blade portion 1A and the support end portion 1B.

  As shown in FIG. 1B, the connecting portion between the blade portion 1A and the support end portion 1B is bent toward the convex side of the curve of the blade portion 1A. That is, the lower surface 1j that is one plate surface of the support end portion 1B is connected to the concave surface 1c of the blade portion 1A, and the upper surface 1k that is the other plate surface of the support end portion 1B is connected to the convex surface 1d of the blade portion 1A. Has been. When the ophthalmic scalpel 1 is horizontally disposed with the lower surface 1j of the support end 1B facing downward, the blade portion 1A as a whole extends obliquely upward.

In the blade portion 1A, the side surface between the concave surface 1c and the convex surface 1d is on the both sides between the tip blade edge portion 1a (blade edge portion) on the tip side and the connecting portion between the tip blade edge portion 1a and the support end portion 1B. The side end blade edge portion 1h (blade edge portion) and the blade side surface 1e are formed in a plane-symmetrical positional relationship.
As shown in FIG. 1 (b), the tip edge portion 1a intersects the concave surface 1c at an acute angle and the convex surface 1d at an obtuse angle in the cross section in the plate thickness direction, and is sharp at the intersection of the tip blade edge portion 1a and the concave surface 1c. A leading edge 1b, which is a sharp cutting edge, is formed.
Moreover, the front-end | tip blade edge | tip part 1a is comprised from the curved surface which makes the circular arc shape convex to the front end side in planar view, as shown to Fig.1 (a).
As shown in FIG. 2, the side end cutting edge 1h is a substantially triangular side surface that intersects the side edge of the tip cutting edge 1a and the concave surface 1c, and the tip cutting edge 1a is in contact with the concave surface 1c. Similarly, it intersects at an acute angle, and a side edge cutting edge 1g which is a sharp cutting edge is formed at the intersection position.
The blade side surface 1e is formed between the end portion of the side end cutting edge portion 1h and the tip end portion of the side surface of the support end portion 1B on the side surface between the concave surface 1c and the convex surface 1d, and the side end cutting edge with respect to the concave surface 1c. It is formed with an acute angle shallower than the portion 1h. However, in this embodiment, the intersection with the concave surface 1c is composed of a side edge 1f which is a corner that is rounder than the side edge cutting edge 1g, and no sharp cutting edge is formed.

  The detailed shape of the support end portion 1B is such that the distal end side is slightly curved in accordance with the arc shape on the proximal end side of the blade portion 1A, and the curvature is reduced toward the proximal end side so that the proximal end portion becomes substantially flat. It has a gently curved shape.

The ophthalmic scalpel 1 is made of an appropriate metal material, such as carbon tool steel or stainless steel, as long as it is a metal material that can be cast. Furthermore, a material whose surface is coated with a hard carbon film, nickel plating or the like for the purpose of rust prevention can be employed for these metal materials.
The blade portion 1A of the ophthalmic scalpel 1 is formed into a thin wall with a thickness t of, for example, about 0.1 mm to 1.5 mm in order to incise the cornea, and at least the tip edge 1a in the vicinity of the tip cutting edge 1b. And the concave surface 1c (θ ′ shown in FIG. 1) is preferably formed at 10 ° to 20 °.
Moreover, the shape of the front end cutting edge 1b and the side end cutting edge 1g needs to be sharp. In particular, the ophthalmic scalpel 1 has a complicated shape compared with a straight scalpel such as a pointed scalpel, and therefore has a small molding shrinkage ratio, excellent molding transferability, and good elasticity after solidification. More preferably, the metal material has
For example, an amorphous alloy material that becomes amorphous by cooling at a cooling rate equal to or higher than the critical cooling rate of the metal material is more preferable. Such an amorphous alloy material is known as a so-called metallic glass material.

As an example of such an amorphous alloy material, a Zr-based alloy containing zirconium (Zr) as a main component (a component occupying the largest proportion in the composition) can be given. Specifically, for example, a composition (atm%) _is able examples of such _{Zr 55 Cu 30 Al 10 Ni 5} , Zr 60 Cu 20 Al 10 Ni 10. Since these amorphous alloy materials are mainly composed of Zr, they are excellent in mold transferability and can be easily formed into complex shapes. Moreover, since nickel (Ni) is added, these are excellent also in chemical resistance.
Further, the amorphous alloy material is not limited to a material mainly containing Zr, and for example, an amorphous alloy material mainly containing titanium (Ti) is also suitable. For example, Ti ₄₀ Zr ₁₀ Cu ₃₆ Pd ₁₄ can be mentioned. This material is particularly excellent in biocompatibility, and is a material suitable for a medical blade used in direct contact with the human body.

Next, the structure of the metal mold | die 2 used for the shaping | molding method of this embodiment is demonstrated.
As shown in FIG. 3A, the mold 2 has mold members 2B and 2D constituting the lower mold arranged adjacent to each other in the horizontal direction, and the mold members 2A and 2C constituting the upper mold are respectively molds. The mold members 2B and 2D are opposed to each other on the upper side and are disposed adjacent to each other in the lateral direction. The metal foil laminate 3 is disposed between the mold member 2A and the mold member 2B.
In the assembled state of the mold 2, the mold members 2 </ b> B and 2 </ b> D and the mold members 2 </ b> A and 2 </ b> C are connected to each other by an unillustrated fixing bolt or the like. It is connected.
Die member 2B, 2A, and metal foil laminates 3 is a member group for forming a molding space S ₁ is a cavity for molding the shape of the blade portion 1A therein when assembled.
Further, the mold member 2D, 2C is a member group for forming a molding space S ₂ is a cavity for molding the shape of the support end portion 1B therein when assembled.

As shown in FIG. 4, the mold member 2 </ b> B has a concave surface molding surface 4 c and mold matching surfaces 2 f and 2 b on the top surface of a rectangular block member in plan view.
The concave surface forming surface 4c is a convex spherical surface that extends in an obliquely upward direction as a whole in the shape of a fan in plan view from the end adjacent to the mold member 2D in order to form the concave surface 1c of the blade portion 1A.
The mold matching surface 2f is a convex cylindrical surface that smoothly connects in the horizontal direction from the upper end side of the concave surface molding surface 4c.
The mold matching surface 2b is a surface that is further extended laterally from the end portions on both sides of the concave surface molding surface 4c and the mold matching surface 2f. The die-matching surface 2b on the side of the concave surface molding surface 4c is a flat surface inclined obliquely upward in accordance with the inclination of the end of the concave surface molding surface 4c. The mold matching surface 2b on the side of the mold matching surface 2f is a horizontal plane.

In addition, the mold member 2D is formed such that a pair of mold-matching surfaces 2c including a horizontal plane connected to each mold-matching surface 2b of the mold member 2B is formed on the upper surface of the rectangular block member in plan view. Further, in order to form the lower surface 1j of the support end 1B between these mold-matching surfaces 2c, from a gentle convex part which is rectangular in plan view and one end side is connected to the arc part at the lower end of the concave part molding surface 4c. A lower surface molding surface 4j is formed.
The material of the mold members 2B and 2D is not particularly limited as long as it is a mold material for performing casting. For example, stainless steel or oxygen-free copper can be used. In the case of performing casting with an amorphous alloy material, a metal material having a thermal conductivity capable of obtaining a cooling rate necessary for amorphization is employed.

FIG. 5 shows the outer shapes of the mold members 2 </ b> A, 2 </ b> C and the metal foil laminate 3 in a state where the vertical direction at the time of assembly is reversed. Therefore, in the description with reference to FIG. 5, unless otherwise specified, the vertical direction is not based on the positional relationship at the time of assembly, but will be described according to the vertical direction in the drawing.
As the molding surface of the mold member 2A, as shown in FIG. 5, a convex surface molding surface 4d and a side molding surface 4e are provided on the upper surface (lower surface when assembled) of the rectangular block member in plan view.
The convex surface forming surface 4d is a concave spherical surface that extends in a downward direction as a whole in a fan shape when viewed from the end on the side adjacent to the mold member 2B in order to form the convex surface 1d of the blade portion 1A.
The side molding surface 4e is a shape of the blade side surface 1e raised to the same height as the plate thickness t of the blade portion 1A slightly obliquely outward from the side of the convex surface molding surface 4d to mold the blade side surface 1e. It is a pair of curved surface along
Further, on the upper surface of the mold member 2A, a pair of mold-matching surfaces 2a, which are planes bent in a V shape for closely contacting the mold-matching surface 2b of the mold member 2B, and the mold member 2B A die matching surface 2e, which is a cylindrical surface in close contact with and in contact with the die matching surface 2f, is formed.

On the lower end side of the convex surface forming surface 4d, a metal foil arrangement surface 5a is formed in order to arrange a part of the metal foil laminate 3. The metal foil arrangement surface 5a is a concave cylindrical surface in which an arc corresponding to the arc shape at a position where the convex surface 1d of the blade portion 1A and the tip edge portion 1a intersect is extended in the horizontal direction.
The metal foil arrangement surface 5a is adjacent to the cylindrical surface of the mold matching surface 2e via a step extending in a direction perpendicular to the generatrix line of the cylindrical surface, and is deep with respect to the mold matching surface 2e. Only t is dug down.
Moreover, since the other part of the metal foil laminated body 3 is arrange | positioned in the side part of the metal foil arrangement | positioning surface 5a, and the both sides of the convex-surface part shaping | molding surface 4d adjacent to the metal foil arrangement | positioning surface 5a, A metal foil arrangement surface 5b dug down in a rectangular shape in plan view by a depth t is provided.
For this reason, the metal foil arrangement surfaces 5a and 5b constitute a U-shaped concave portion opened to the convex surface molding surface 4d side when the mold member 2A is viewed from above in FIG.

Further, as shown in FIG. 5, the shape of the mold member 2C is a pair of mold-matching surfaces comprising a horizontal plane connected to each mold-matching surface 2a of the mold member 2A on the upper surface of the rectangular block member in plan view. 2d is formed. In addition, between the mold matching surfaces 2d, in order to form the upper surface 1k of the support end 1B, a gentle convex portion that is rectangular in plan view and has one end connected to the arc portion at the lower end of the concave surface forming surface 4c. A lower surface molding surface 4j is formed.
As the material of the mold members 2A and 2C, the same metal material as that of the mold members 2B and 2D can be adopted.

The metal foil laminate 3 is obtained by laminating a plurality of metal foils on the metal foil arrangement surfaces 5a and 5b of the mold member 2A. In this embodiment, as shown in FIG. , Metal foils 3A, 3B, 3C, 3D, and 3E (hereinafter collectively referred to as “laminated body lower surface 3f arranged on metal foil arrangement surface 5a”). In some cases, it may be referred to as metal foil 3A or the like).
Further, as shown in FIG. 5, the metal foil laminate 3 is formed so that the metal foil 3A or the like is cut into a U-shape and laminated so as to be fitted into the concave shape of the metal foil arrangement surfaces 5a and 5b. Has been.
In addition, on the inner periphery facing the U-shaped opening, there are a tip cutting edge part forming surface 4a for forming the shape of the tip cutting edge part 1a of the blade part 1A, a side edge cutting edge part 1h and a side edge cutting edge of the blade part 1A. A pair of side end cutting edge forming surfaces 4h for forming a part of the shape of the blade side surface 1e adjacent to the portion 1h is formed.
In the present embodiment, the shapes of the tip edge part molding surface 4a and the side edge edge part molding surface 4h are formed by laminating metal foils 3A and the like in a step shape.

For this reason, the metal foil 3A or the like has a U-shaped outer cut end 3h along the step portion between the metal foil placement surfaces 5a and 5b and the mold matching surfaces 2e and 2b in common.
Further, the three inner sides of the U-shaped metal foils 3A, 3B, 3C, 3D, and 3E have inner cut ends 3a, 3b, 3c, 3d, and 3e (hereinafter referred to as inner cut ends 3a, etc.) having different shapes. May be collectively referred to). As a result, a step-like cross section that is inclined toward the outer cut end 3h from the laminate lower surface 3f toward the laminate upper surface 3g is formed. For example, as shown in FIG. 3 (b), a stepped cross section in which the inner cut ends 3a, 3b, 3c, 3d, and 3e are located in this order toward the outer cut end 3h is formed on the tip cutting edge forming surface 4a. ing.
Further, although not shown in detail, a similar stepped cross section is also formed on the side edge cutting edge forming surface 4h.

The thickness of the metal foil laminate 3 is set to be slightly thicker than the step size t of the metal foil arrangement surfaces 5a and 5b before assembly. For example, when t = 0.15 mm, the thicknesses t _A , t _B , t _C , t _D , and t _E of the metal foils 3A, 3B, 3C, 3D, and 3E are all set to 0.035 mm. The difference of 0.025 mm (= 0.035 × 5-0.15) between the total and the step size t is eliminated by deformation of the metal foil 3A or the like due to the pressing force during mold clamping.
In this embodiment, since the level | step difference of the metal foil laminated body 3 is transcribe | transferred to a blade edge | tip part, each thickness of metal foil 3A etc. is set so that the unevenness | corrugation of the surface of a blade edge | tip part may become a tolerance | permissible_range. Further, the thickness of the metal foil 3E constituting the upper surface 3g of the laminated body and the shape of the inner cutting edge 3e are transferred to the molded product to form the leading edge cutting edge 1b and the side edge cutting edge 1g, and thus have the necessary sharpness. Set to obtain.

As the material of the metal foil 3A and the like, an appropriate metal foil can be adopted as long as it is a metal foil that is not melted when it is in contact with the molten metal that forms the ophthalmic knife 1. For example, copper foil (melting point: 1084 ° C., thermal conductivity: 398 W / (m · K)), silver foil (melting point: 962 ° C., thermal conductivity: 420 W / (m · K)), gold foil (melting point: 1064 ° C., Thermal conductivity: 320 W / (m · K)) or the like can be employed.
In addition, the metal foil 3A and the like can be formed by laminating one kind of material among such copper foil, silver foil, and gold foil. However, in the present embodiment, the material types are stacked to be stacked, and the metal foil having a material having a higher thermal conductivity is stacked so as to be closer to the layer that forms the front end cutting edge 1b and the side end cutting edge 1g. . As an example, for example, the metal foils 3A and 3B can be made of gold foil, the metal foils 3C and 3D can be made of copper foil, and the metal foil 3E can be made of silver foil.

Next, a method for forming the medical knife of the present embodiment, which is a method for manufacturing the ophthalmic knife 1 (hereinafter simply referred to as a forming method), will be described.
The molding method of the present embodiment is a molding method using a mold having a cavity for molding a medical blade having a cutting edge, and includes a first mold assembly process, a second mold assembly process, And a molding process in this order.

In the first mold assembling step, the metal foils 3A, 3B, 3C, 3D, and 3E are laminated on the metal foil arrangement surfaces 5a and 5b of the mold member 2A. Thereby, the metal foil laminated body 3 is arrange | positioned on the mold member 2A. As a result, a mold subassembly composed of the mold member 2A and the metal foil laminate 3 is formed. Next, the upper mold of the mold 2 is formed by connecting the subassembly and the mold member 2C.
Thus, the first mold assembly process is completed.

In this step, the way of laminating the metal foil 3A and the like is not particularly limited.
For example, the metal foil 3A is placed on and closely adhered to the shape of the metal foil arrangement surfaces 5a and 5b by arranging the metal foil 3A on the metal foil arrangement surfaces 5a and 5b and using an appropriate jig. Similarly, the metal foils 3B, 3C, 3D, and 3E may be sequentially stacked one by one.
Between the metal foil arrangement surfaces 5a and 5b and the metal foil 3A, and between the metal foil 3A and the like, the metal foil 3A has flexibility, ductility and smoothness, and is a contact between the metal surfaces. Therefore, it can be made to adhere well only by lightly pressing.

Further, for example, the metal foil 3A and the like are laminated in advance at a place different from the mold member 2A to form the metal foil laminate 3 as shown in FIG. The lower surface 3f is disposed on the metal foil arrangement surfaces 5a and 5b, the laminate upper surface 3g of the metal foil laminate 3 is pressed, and the laminate lower surface 3f is brought into close contact with the metal foil arrangement surfaces 5a and 5b. You may install in the mold member 2A at once.
In this case, the metal foil laminate 3 has a positioning jig for positioning the outer cut end 3h of the metal foil 3A and the like whose outer shape is formed in advance, and a lamination jig having a lamination base having releasability with respect to the metal foil 3A. Above, the layers may be sequentially stacked. Further, the metal foil laminate 3 is once laminated into a flat plate shape in this way, and then pressed according to the shape of the metal foil arrangement surfaces 5a and 5b to be shaped into a shape along the metal foil arrangement surfaces 5a and 5b. In addition, after the laminated layers are brought into close contact with each other, they may be arranged on the mold member 2A.

  In this step, a metal foil laminate 3 in which a plurality of metal foils are laminated is placed on a mold member 2A that forms a part of the cavity, and the shapes of the tip edge part 1a and the side edge edge part 1h, which are the edge parts, are arranged. The tip edge part forming surface 4a and the side end edge part forming surface 4h, which are the blade edge part forming surfaces for forming the respective parts, are formed, and the subassembly of the mold 2 is assembled.

Next, a second mold assembly process is performed.
In this step, the mold members 2B and 2D are assembled to the partial assembly composed of the mold member 2A and the metal foil laminate 3 assembled in the second mold assembly step and the mold member 2C, respectively.
At this time, the mold member 2B may be assembled after being connected to the mold member 2D, or may be assembled separately from the mold member 2D.

By such assembly, the mold matching surfaces 2b and 2f of the mold member 2B are brought into contact with the mold matching surfaces 2a and 2e of the mold member 2A, respectively.
Further, the mold matching surface 2a, the laminate top 3g of the metal foil laminate 3, which is slightly protruded from 2e is die matching surface 2b in the metal foil laminated body pressure region P ₁ shown in FIG. 4 by a two-dot chain line, 2f Abut. For this reason, the metal foil laminate 3 is pressed and compressed in the laminating direction so that the mold matching surfaces 2b and 2f and the laminate upper surface 3g are in close contact with each other, and the adhesion between the layers of the metal foil laminate 3 is enhanced. .

In this way, the mold ₂ having the molding spaces S ₁ and S ₂ as shown in FIG. The molding space _{S 1,} as shown in FIG. 3 (b), a metal foil laminate 3 of the inner cutting edge 3a, 3b, 3c, 3d, stepped tip cutting edge forming surface 4a is formed by 3e .
Similarly, a step-shaped side end cutting edge forming surface 4h (see FIG. 5) is formed by the inner cut ends 3a, 3b, 3c, 3d, and 3e of the metal foil laminate 3.

Thus, the second mold assembly process is completed.
This process is a mold that is another mold member so as to press the metal foil laminate 3 with the metal foil laminate 3 sandwiched between the subassembly assembled in the first mold assembling step. The mold member 2B is attached, and the mold ₂ having the molding spaces S ₁ and S ₂ as cavities is assembled.

Next, a molding process is performed.
This step is a step of performing molding by injecting a molten metal material into the cavity of the mold 2 assembled in the second mold assembling step.
In this embodiment, as shown in FIG. 3A, molten metal 6M, which is a molten metal material, is injected from an opening communicating with the molding space S2 formed on the outer peripheral surface of the mold ₂ . The material of the molten metal 6M, as an example, the composition is used _Zr 55 _Cu 30 _Al 10 Ni ₅ a is Zr alloy. In this case, the temperature of the molten metal 6M is preferably 1050 ° C.
The injection method of the molten metal 6M is not particularly limited, and an injection molding method, a centrifugal casting method, or the like can be used. In this embodiment, the centrifugal casting method is adopted, and the mold 2 is arranged in a centrifugal casting apparatus (not shown). Then, the molten metal 6M is injected by centrifugal force.

Injected into the molding space S ₂ was melt 6M is a bottom portion forming surface 4j, while being quenched by contact with the upper surface portion forming surface 4k, it is injected into the molding space S ₁ in a short time. The forming space S within _1, the concave portion forming surface 4c, the convex portion forming surface 4d, in contact with the side molding surfaces 4e, while being further sudden cooling, the tip cutting edge forming surface 4a, the position of the side end edge portion forming surface 4h (See FIG. 6).
Incidentally, the melt 6M is to reach the molding space _{S 1,} is cooled below the silver foil having a melting point in the molding space _{S 2} from 1050 ° C.. For this reason, even if the metal foil 3 is a silver foil, there is no possibility of being melted by the heat of the molten metal 6M.
Further, when the heat conduction to the mold 2 proceeds and the molten metal 6M reaches the solidification temperature, the solidified body 6 is formed in close contact with the shape of the inner peripheral surface of the molding spaces S ₁ and S ₂ .
When the solidified body 6 is cooled to a temperature at which the shape is stabilized, the mold 2 is divided, and the solidified body 6 is removed from the mold 2.
This completes the molding process.

By the way, the cavity assembled with a plurality of mold members generally has a minute gap on the mold dividing surface of the mold member. For this reason, the molten metal 6M easily enters the mold dividing surface, and when this solidifies, it becomes a burr on the surface of the molded product. Even a slight burr on the cutting edge affects the sharpness, so that the conventional technique cannot be formed only by molding.
In the present embodiment, in the second mold assembling step, the metal foil laminate 3 is assembled in a state of being pressed between the mold members 2A and 2B. For this reason, the metal foil 3A is brought into close contact with the metal foil arrangement surfaces 5a and 5b in a state of following the minute irregularities remaining in the processing of the metal foil arrangement surfaces 5a and 5b due to the ductility of the metal foil 3A. Moreover, die matching surface 2b, the metal foil laminate pressing region P ₁ of 2f, die matching surface 2b metal foil 3E is similarly be adhered to 2f. Moreover, since adjacent metal foils, such as metal foil 3A, are further smaller than the surface of a metal mold | die member, they are closely_contact | adhered without gap.
Therefore, the molten metal 6M enters between the metal foil laminate 3 and the mold member 2A, between the metal foil laminate 3 and the mold member 2B, and between each metal foil of the metal foil laminate 3. I can't. As a result, burrs do not occur at these positions.

Therefore, since the shape of the inner cut end 3a of the metal foil 3A is accurately transferred to the solidified body 6, the front end cutting edge 1b, which is a sharp cutting edge along the shape of the inner cut end 3e, and the side end cutting edge 1 g is formed. In addition, the leading edge edge portion 1a and the side edge edge portion 1h accurately transfer the stepped slope shape of the leading edge edge portion molding surface 4a and the side edge blade edge portion molding surface 4h.
For this reason, the solidified body 6 is formed into a shape that can be used as the ophthalmic scalpel 1 by forming the shape of the cutting blade at least at the cutting edge without performing secondary processing such as grinding or polishing. Yes.
However, for example, when burrs or the like are generated at the base end portion of the support end portion 1B into which the molten metal 6M has been injected, the side surface of the support end portion 1B, the side end edge 1f, or the like, the solidified body 6 is removed. After molding, shaping and deburring. These secondary processes are different from the cutting edge and the cutting edge part, and do not need to be performed with high accuracy, and therefore can be performed in a short time.
In this way, the ophthalmic knife 1 is obtained.

In the present embodiment, the metal foil 3A or the like of the metal foil laminate 3 is made of a material such as the metal foil 3A or the like so that the thermal conductivity increases as it approaches the layer that forms the front end cutting edge 1b and the side end cutting edge 1g. Selected.
Due to such a change in the thermal conductivity, the molten metal 6M is moved along the tip edge portion molding surface 4a and the side edge blade edge portion molding surface 4h, and the inner cut ends 3e of the metal foils 3A, 3B, 3C, 3D and the metal foil 3E. While contacting in this order, the cooling rate for the molten metal 6M increases in this order.
As a result, the heat insulating property on the metal foil 3A side is relatively high on the leading edge cutting edge forming surface 4a and the side edge cutting edge forming surface 4h, and the molten metal 6M is hardly cooled, and the molten metal 6M has the inner cut edge 3e. High fluidity can be maintained until it reaches. Therefore, the molten metal 6M is satisfactorily filled up to the vicinity of the inner cut end 3e. Thereby, the shape of the sharp end cutting edge 1b and the side end cutting edge 1g is obtained.
Note that such a difference in thermal conductivity is a relative difference between the tip edge portion molding surface 4a and the side edge tip portion molding surface 4h, and the metal foil laminate 3 as a whole has good thermal conductivity. doing. When it actually shape | molded on the conditions of this embodiment and measured the X-ray diffraction of the blade edge | tip part, it did not show a sharp peak and it was confirmed that the amorphous body was formed.
For this reason, the molten metal 6M is also cooled at a cooling rate higher than the critical cooling rate necessary for solidifying as an amorphous alloy on the leading edge cutting edge forming surface 4a and the side edge cutting edge forming surface 4h. It was confirmed.

  Moreover, in this embodiment, the shape of the front-end | tip edge part 1a, the front-end cutting edge 1b, the side-end cutting edge part 1h, and the side-end cutting edge 1g which require a highly accurate process in the scalpel 1 is used for the metal foil laminate 3. Can be formed. Therefore, the configuration of the processed surfaces of the mold members 2A, 2B, 2C, and 2D is simplified, and the manufacture of these mold members is facilitated. For this reason, among the medical blades, for example, it is a molding method suitable for forming a blade edge portion and a blade edge having a complicatedly curved shape like the ophthalmic knife 1.

[First Modification]
Next, a modified example (first modified example) of the present embodiment will be described.
FIGS. 7A and 7B are process explanatory views for explaining a smoothing process of a modified example (first modified example) of the method for forming a medical blade according to the first embodiment of the present invention. FIG. 8 is a schematic cross-sectional view showing a configuration of a main part of a mold used in a modified example (first modified example) of the method for forming a medical blade according to the first embodiment of the present invention.

  In the first mold assembly step in the first embodiment, the forming method of the present modified example is configured such that the metal foil laminate 3 is disposed after the metal foil laminate 3 is disposed in order to form the blade edge portion forming surface. The forming method further includes a smoothing step of pressurizing and smoothing the end of each layer such as the metal foil 3A to be configured. Hereinafter, a description will be given centering on differences from the first embodiment.

In this modification, first, similarly to the first mold assembling step of the first embodiment, the metal foil laminate 3 is disposed on the mold member 2A, and the laminate lower surface 3f is brought into close contact therewith. Thereby, the step-like slope similar to the tip edge part molding surface 4a and the side edge edge part molding surface 4h of the first embodiment is formed. FIG. 7A shows a state in which the laminate lower surface 3f is in close contact with the metal foil arrangement surface 5a.
Next, a smoothing process is performed. In this step, the inner cut end 3a and the like of the metal foil laminate 3 are pressed toward the metal foil arrangement surface 5a using the rolling jig 7 having a convex curved surface on the surface.
Thereby, as shown in FIG.7 (b), the vicinity of the inner side cut end 3a etc. is rolled, and each is smoothed diagonally. That is, smooth end surfaces 3a ′, 3b ′, 3c ′, 3d ′, and 3e ′ are formed at the tips of the metal foil 3A and the like, and a curved surface in which these are smoothly connected is formed.

In FIG. 7 (b), the tip blade edge forming surface 4a made of a convex curved surface is formed on the metal foil arrangement surface 5a side. The curved direction and the curvature are the steps of the metal foil 3A and the like. It can be easily changed depending on the shape of the cross section. That is, the average inclination of the stepped cross section is the shape of the curved surface obtained by rolling.
In this modification, as shown in FIG. 3B, the intervals between adjacent ones of the inner cut ends 3e, 3d, 3c, 3b, and 3a are increased in this order. For this reason, the convex curved surface is formed in the metal foil arrangement | positioning surface 5a side by rolling these uniformly.
If the intervals between adjacent ones of the inner cut ends 3d, 3c, 3b, and 3a are equalized, it is possible to form the tip edge portion molding surface 4a that is inclined linearly.

Although not particularly illustrated, a stepped slope similar to the side edge cutting edge forming surface 4h is also pressed by the rolling jig 7, and the side edge cutting edge forming surface 4H (see FIG. 5), which is the same smooth surface, is used. Form.
Thus, the first mold assembling process of this modification is completed.

Next, a second mold assembling step is performed in the same manner as in the first embodiment. As a result, a molding space S ₁ ′ (cavity) as shown in FIG. 8 is formed.
Next, a molding process is performed in the same manner as in the first embodiment.

According to this modification, in order to form the smoothed front edge portion molding surface 4a and side end edge portion molding surface 4H by the smoothing step, this shape is transferred to the molded product and smoothed by the molding step. The leading edge edge 1a and the side edge edge 1h are formed. Further, the tip cutting edge 1b and the side edge cutting edge 1g are sharper than the first embodiment because the radius of curvature of the cutting edge is smaller than the thickness of the metal foil 3E.
According to this modification, even if the thickness of the metal foil 3A or the like is large, a smooth cutting edge can be formed and a sharper blade can be formed compared to the thickness of the metal foil. The number of metal foils constituting the foil laminate 3 can be reduced. For this reason, it becomes easier to form the metal foil laminate 3.

[Second Embodiment]
Next, a method for forming a medical blade according to the second embodiment of the present invention will be described focusing on differences from the first embodiment.
FIGS. 9A and 9B are a schematic front view and a back view illustrating an example of a medical blade formed by the method for forming a medical blade according to the second embodiment of the present invention, respectively. . FIG.9 (c) is DD sectional drawing in Fig.9 (a). FIG. 10 is a schematic front view showing a holding member for a medical blade according to the second embodiment of the present invention. 11 (a), (b), (c), and (d) are a schematic front view, back view, and left side of a mold used in the method for forming a medical blade of the second embodiment of the present invention, respectively. It is a side view and a right side view. Fig.12 (a) is EE sectional drawing in Fig.11 (a). FIGS. 12B and 12C are a cross-sectional view taken along line FF and a partial enlarged view of the G portion in FIG. FIGS. 13A and 13B are a schematic right side view and a front view showing a state in which a gripping member is arranged on a mold used in the method for forming a medical blade according to the second embodiment of the present invention. is there. FIG. 14 is a process explanatory view taken along the line H-H in FIG. 13B, illustrating a forming process in the method for forming a medical blade according to the second embodiment of the present invention.

  The method for molding a medical knife of the present embodiment (hereinafter simply referred to as a molding method) is suitable for manufacturing the medical knife 10 (medical knife) shown in FIGS. 9 (a), (b), and (c). Is a molding method that can be used for

The medical knife 10 is a circular knife used for skin incision, for example, and includes a blade part 11A, a support part 11B, and a pair of gripping members 12.
As shown in FIG. 9A, the blade portion 11A includes a blade side surface 11c whose shape in front view is a half-moon shape, and a blade edge portion 11a formed along the arc shape of the tip of the blade side surface 11c. It is provided on the front side and the back side in FIG.
In the present embodiment, the maximum thickness of the pair of cutting edge portions 11a is 1.0 mm.
The tips of the pair of blade tips 11a intersect each other in a V shape, thereby forming a sharp cutting edge 11b having a circular arc shape in the front view and a straight shape (see FIG. 9B) in the back view. ing. The V-shaped angle of the pair of blade edges 11a is preferably 20 ° to 40 °.
In the present embodiment, the pair of blade side surfaces 11c are inclined so as to swell toward each other toward the cutting blade 11b side and the opposite side to the support portion 11B. A top surface 11d is formed between the pair of blade side surfaces 11c at the end opposite to the blade edge portion 11a.

The support portion 11B is formed in an elongated and substantially flat plate shape having a rectangular cross section with a width w ₂ and a thickness t _{2 that} extends in parallel to the cutting edge 11b from the end portion of the blade portion 11A. The support part upper surface 11e which is one side surface of the support part 11B in the width direction is aligned with the top surface 11d of the blade part 11A.
In the present embodiment, the support portion 11B and the blade portion 11A are made of the same material and are integrally molded by the molding method of the present embodiment.
Moreover, as shown in FIG.9 (c), the molten metal with which the recessed part 12a mentioned later of the holding member 12 was solidified by the side surface of the thickness direction of the support part 11B was solidified, and several engaging part 11g Is formed.
As the material of the blade part 11A and the support part 11B, the same metal material as that of the ophthalmic knife 1 of the first embodiment can be adopted.

The gripping member 12 is a pair of plate-like members provided for gripping the medical knife 10 without touching the blade portion 11A. The gripping member 12 has a rectangular cross section with a width w ₁ (where w ₁ ≧ w ₂ ) and a thickness t ₁ , covers the support portion 11B in the longitudinal direction, and sandwiches the support portion 11B from both sides in the thickness direction. It is attached with.
Moreover, the edge part of the width direction of the holding member 12 is located in the outer side rather than the support part upper surfaces 11e and 11f which are all the side surfaces of the support part 11B in the width direction.
In the present embodiment, the gripping member 12 is placed in a mold for molding the medical knife 10 and cast-molded, so that the support member 11B and the support portion 11B are attached to the mounting surface 12e that is one side surface in the thickness direction. It is attached closely.

Further, as shown in FIGS. 9A and 10, an elliptical side opening 12 c is formed on the outer surface 12 d, which is the side surface opposite to the attachment surface 12 e in the thickness direction of the grip member 12. Are provided at three locations at intervals in the longitudinal direction.
As shown in FIG. 9C, the cross section in the thickness direction of the gripping member 12 at the side opening 12c is formed with a concave hole portion 12a formed of a cylindrical hole that obliquely penetrates from the mounting surface 12e toward the outer surface 12d. Has been. The inclination direction of the recessed hole portion 12a is set to an oblique direction so as to approach the blade portion 11A in the longitudinal direction of the gripping member 12 from the attachment surface 12e.
Further, on the inner peripheral side of the side surface opening 12c, a step portion dug down from the side surface opening 12c to the mounting surface 12e side is formed on the side opposite to the blade portion 11A, and this step portion is formed with the inner peripheral surface of the recessed hole portion 12a. Crossed. Thus, an engagement protrusion 12b is formed inside the gripping member 12 so as to protrude from the inner peripheral surface of the side opening 12c toward the blade portion 11A when the gripping member 12 is viewed from the outer surface 12d.
As the material of the gripping member 12, an appropriate material can be adopted as long as it does not melt even when it comes into contact with the molten metal for forming the blade portion 11A and the support portion 11B. In the present embodiment, stainless steel SUS316L (thermal conductivity: 16.3 W / (m · K)) is employed.

Next, the configuration of the mold 20 used in the molding method of this embodiment will be described.
As shown in FIGS. 11A, 11B, and 11C, the mold 20 has a blade part mold part 20A for forming the shape of the blade part 11A and a gripping member 12 disposed therein. And a mold member 20B for forming the support portion 11B. These are connected in the horizontal direction by connecting means (not shown), and are provided in an elongated rectangular parallelepiped shape along the longitudinal direction of the medical knife 10 as a whole.

As shown in FIGS. 12A and 12B, the blade portion mold portion 20A has side surface forming surfaces 24b for forming the shape of the blade side surface 11c, and the side surface forming surfaces 24b are arranged to face each other. Metal foil laminated portion 23 provided between the side surface mold members 20R and 20L and the side surface mold members 20R and 20L to form the shapes of the blade edge portion 11a and the cutting edge 11b, and the top A top surface mold member 20T having a top surface molding surface 24d for molding the shape of the surface 11d.
The top surface mold member 20T is a plate-like member disposed on one end side of the side surface mold members 20R and 20L so as to cover the side surface molding surfaces 24b.
The side surface mold members 20R and 20L and the top surface mold member 20T are assembled in a state where they are pressed against each other by a bolt or a pressing plate (not shown).

As shown in FIG. 12 (a), the side surface molding surfaces 24b of the side surface mold members 20R and 20L are arranged on the vertical surface when the blade portion mold part 20A is placed in a positional relationship in which the top surface 11d is aligned with the horizontal surface. On the other hand, it is inclined obliquely.
Further, as shown in FIG. 12 (b), the lower side of each side surface forming surface 24b has an arc shape corresponding to the boundary between the blade side surface 11c and the blade edge portion 11a. A metal foil arrangement surface 24c made of a plane along the vertical direction is formed (see FIG. 12C).

As shown in FIG. 12 (c), the metal foil laminate portion 23 has metal foil laminates 23R, 23L in which a plurality of metal foils are laminated on the respective metal foil arrangement surfaces 24c of the side surface mold members 20R, 20L. Are opposed to each other, and a pair of cutting edge portion forming surfaces 24a having a V-shaped cross section for forming the shapes of the cutting edge portion 11a and the cutting edge 11b are formed. That is, the V-shaped angle θ ″ (see FIG. 12C) of the cutting edge portion molding surface 24a is set in accordance with the V-shaped angle of the pair of cutting edge portions 11a.
Hereinafter, in the metal foil laminates 23R and 23L, for convenience, a surface that is in close contact with the metal foil arrangement surface 24c is referred to as a laminate lower surface 23f. The surface on which the metal foil laminates 23R and 23L are in close contact with each other is referred to as a laminate upper surface 23e.

In the metal foil laminate 23R, metal foils 23Ra, 23Rb, and 23Rc are laminated in this order from the laminate lower surface 23f to the laminate upper surface 23e.
When viewed from the laminating direction, the end surface on the side molding surface 24b side of the metal foil laminate 23R has an arc shape along the end of the side molding surface 24b (see FIG. 12B). In the cross section along the stacking direction, as shown in FIG. 12C, inclined end surfaces 23a, 23b, and 23c of the metal foils 23Ra, 23Rb, and 23Rc are formed along the blade edge forming surface 24a.
Further, the metal foil laminate 23L has a shape in which the shape of the metal foil laminate 23R is plane-symmetric with respect to the laminate upper surface 23e. That is, the metal foils 23La, 23Lb, and 23Lc having shapes symmetrical to the metal foils 23Ra, 23Rb, and 23Rc are laminated in this order from the lower surface 23f side of the laminated body, whereby the cutting edge portion molding surface 24a is formed at each end. Inclined end faces 23a, 23b, and 23c are formed.

Further, as the material of the metal foils 23Ra, 23Rb, 23Rc, 23La, 23Lb, and 23Lc, the same material and combination of materials as the metal foil 3A and the like in the first embodiment can be adopted.
In the present embodiment, a gold foil having a thickness of 12 μm is employed for the metal foil 23Ra (23La), a copper foil having a thickness of 10 μm is employed for the metal foil 23Rb (Lb), and a silver foil having a thickness of 10 μm is employed for the metal foil 23Rc (Lc). ing. For this reason, similarly to the first embodiment, the cutting edge portion molding surface 24a is laminated with a metal foil having a material having a higher thermal conductivity as it approaches the layer forming the cutting edge of the cutting edge portion.

With such a configuration, a molding space S ₃ (cavity) composed of a pair of side surface molding surfaces 24b, a pair of blade edge portion molding surfaces 24a, and a top surface molding surface 24d is formed inside the blade portion mold portion 20A. Is formed.

The mold member 20B, as shown in FIG. 11 (a), (b) , (d), for inserting the gripping member 12 in close contact with the internal, slightly larger than the width _{w 1} of the gripping member 12 width W _1, rectangular cross section of thickness t ₁ than slightly larger width T ₁ of the gripping member 12, gripping member placement hole 20a of a pair which penetrates in the longitudinal direction of the mold member 20B (grip member placement portion) is provided opposite to the direction of width T _1.
Further, between these gripping members arranged holes 20a, the are spaced by the thickness t ₂ of the supporting portion 11B of the medical knife 10, also the direction along the width W ₁ between each (vertical direction in the drawing), to form the support part upper surface 11e and the support lower surface 11f of the supporting portion 11B, the support portion forming surface 20b, 20c are formed protruded at intervals _{w 2} in a direction along the width _{W 1.}

Thus, the shape of the mold member 20B is an H-shaped penetrating shape in which the outer peripheral shape is a prismatic shape and is surrounded by a pair of gripping member arrangement holes 20a and support portion molding surfaces 20b and 20c at the center. It is a cylindrical shape provided with holes.
However, the mold member 20B is assembled so as to be appropriately divided in order to take out a molded product after molding.

Next, the molding method of the present embodiment is a molding method using a mold having a cavity for molding a medical blade having a cutting edge, and includes a first mold assembling step and a second mold. In this method, the assembly process, the gripping member arrangement process, and the molding process are performed in this order.
However, in the first and second mold assembling steps, the ophthalmic knife 1 and the medical knife 10 are different in the shape of the molded product, and based on this, the difference due to the difference in the structure of the molds 2 and 20 is excluded. These are essentially the same as the respective steps in the first modification of the first embodiment.

In the first mold assembling step, the metal foils 23Ra, 23Rb, and 23Rc are stacked on the cutting edge portion forming surface 24a of the side surface mold member 20R by using the same stacking method as in the first embodiment. Thereby, the 1st partial assembly by which the metal foil laminated body 23R is arrange | positioned on the side surface part mold member 20R is formed.
At this time, in the metal foils 23Ra, 23Rb, and 23Rc, as in the first embodiment, the inner cut end on the side molding surface 24b side has a stepped slope from the laminate upper surface 23e toward the laminate lower surface 23f. Cut into the shape to be formed. In this case, in this modification, in order to make the inclination of the blade edge portion molding surface 24a constant, the interval between the adjacent inner cut ends is made constant, and the inner slopes are made constant so that the average inclination of the stepped cross section becomes constant. The shape of the cut end is adjusted.
Next, a smoothing process is performed. That is, similarly to the first modification of the first embodiment, the end portions of the respective layers of the metal foils 23Ra, 23Rb, and 23Rc constituting the metal foil laminate 23R are pressurized and smoothed. Thereby, the blade edge | tip part molding surface 24a of the metal foil laminated body 23R is formed.

Similarly, metal foils 23La, 23Lb, and 23Lc are laminated on the cutting edge forming surface 24a of the side surface mold member 20L. As a result, a second partial assembly in which the metal foil laminate 23L is arranged on the side surface mold member 20L is formed. And the smoothing process is performed similarly to the 1st partial assembly, and the blade edge | tip part shaping | molding surface 24a is formed in the metal foil laminated body 23L.
Thus, the first mold assembling process is completed.

Next, a second mold assembly process is performed.
In this step, the first and second subassemblies assembled in the first mold assembling step are brought into close contact with the respective laminate upper surfaces 23e so that the metal foil laminates 23R and 23L are aligned in the stacking direction. Install it so that it is in close contact. Thereby, the side surface mold members 20R and 20L are assembled to each other, and the metal foil laminated portions 23R and 23L are arranged in a positional relationship in which each blade edge portion molding surface 24a forms a V-shaped cross section. It is formed. As a result, molding surfaces corresponding to the cutting edge portion 11a and the cutting edge 11b of the medical knife 10 are formed.
Next, with respect to the assembly of the side surface mold member 20R, the metal foil laminated portion 23, and the metal foil laminated body 23L assembled in this way, the top surface mold member is covered so as to cover each side surface molding surface 24b. Assemble 20T. Thus, the blade portion mold unit 20A having a molding space S ₃ of forming the shape of the blade portion 11A is obtained.
Next, the mold 20 is assembled by connecting the blade part mold part 20A and the mold member 20B having the pair of gripping member arrangement holes 20a.
Thus, the second mold assembly process is completed.

Next, a holding member arrangement process is performed.
This step is a step of placing the gripping member 12 in the gripping member placement hole 20a of the mold 20 assembled in the second mold assembly step between the second mold assembly step and the molding step. .
In the present embodiment, as shown in FIGS. 13A and 13B, the gripping members 12 are inserted into the gripping member arrangement holes 20a provided in the mold member 20B of the mold 20, respectively. Since the holding member arrangement hole 20a is opened in a rectangular shape having a width W ₁ × thickness T ₁ slightly larger than the width w ₁ × thickness t ₁ , the holding member 12 is between the holding member arrangement hole 20a. In addition, it can be smoothly inserted without generating a substantial gap.
At this time, the direction of each gripping member 12 is such that each mounting surface 12e faces inward, and as shown in FIG. 14, the inclination direction of the recessed hole portion 12a is directed toward the blade portion mold portion 20A side. It arrange | positions so that it may become the direction which goes to the outer surface 12 side from the attachment surface 12e.
Thereby, a rectangular cross section of width w ₂ × thickness t ₂ surrounded by the attachment surface 12e of each gripping member 12 and the support portion molding surfaces 20b and 20c is formed inside the mold member 20B. molding space S ₄ communicating with the molding space S ₃ of the blade portion mold unit 20A along the longitudinal direction is formed.
The molding spaces S ₄ and S ₃ constitute a cavity of the mold 20 for molding the shapes of the blade part 11A and the support part 11B.
Thus, the gripping member arranging process is completed.

Next, the molding process is performed in the same manner as in the first embodiment.
That is, the mold 20 on which the holding member 12 is arranged is attached to a centrifugal casting apparatus (not shown). Then, as shown in FIG. 14, and heated from the opening end of the die member 20B which communicates with the molding space _{S 4,} a Zr-based alloy composition is _Zr 55 _Cu 30 _Al 10 Ni ₅ to 1050 ° C. melt 6M is injected by centrifugal force.

Injected into the molding space S ₄ were melt 6M is filled toward the molding space S3 of the downstream side along the longitudinal direction of the molding space S _4. At this time, the molten metal 6M is cooled in contact with the support portion molding surfaces 20b and 20c and the attachment surface 12e of the gripping member 12.
However, the gripping member 12, since in comparison with the material of the mold member 20B is formed with SUS316L low thermal conductivity, in the molding space S within _4, the molten metal 6M is cooled in comparison with the case where there is no gripping member 12 Hateful. As a result, the melt 6M is, while maintaining the high fluidity, reaches the molding space S ₃ on the back side, the cutting edge portion forming surface 24a of the molding space S _3, is suddenly cooled in contact with the side molding surfaces 24b, It solidifies as an amorphous alloy along the shape of these molding surfaces.
As with the first embodiment, the cutting edge portion forming surface 24a is formed by laminating metal foils having a material having a higher thermal conductivity as it approaches the layer forming the cutting edge of the cutting edge portion. The metal foils 23Rc and 23Lc forming the blade 11b are reliably filled, and the shape of the blade edge portion molding surface 24a is accurately transferred to form the shapes of the blade edge portion 11a and the cutting edge 11b.
Thereby, the shape of the blade portion 11A is formed.

On the other hand, in the molding space S _4, the molten metal 6M proceeding from upstream to downstream along the mounting surface 12e, as shown in FIG. 14, is filled along the recessed hole portions 12a.
At this time, the recessed hole portion 12a has an acute angle with respect to the flow path of the molten metal 6M and has a shape that branches from the upstream side to the downstream side in the injection direction of the molten metal 6M. Is smoothly branched.
The molten metal 6M branched into the concave hole portion 12a contacts the mold member 20B having a thermal conductivity higher than that of the grip member 12 in the side surface opening 12c, and is rapidly cooled and solidified. As a result, the shape of the engaging portion 11g is formed.
Temperature of the melt 6M last the molding space S ₄ is, when cooled below the solidification temperature, molten metal 6M is solidified along the shape of the molding space S _3, the shape of the supporting portion 11B is molded.
Further, the engaging portion 11g is formed by solidifying the molten metal 6M so as to go around from the recessed hole portion 12a to the engaging protrusion 12b, so that each gripping member 12 is attached to the mounting surface in a state of being prevented from being detached by the engaging portion 11g. At 12e, it is in close contact with the support portion 11B.
Thus, when it cools to the temperature which the shape of a solidified body becomes stable, the metal mold | die 20 will be divided | segmented and a solidified body will be demolded from the metal mold | die 20. FIG.
This completes the molding process.

  As described above, in the molding process of the present embodiment, the molten metal 6M is injected along the attachment surface 12e which is the surface of the gripping member 12 arranged in the gripping member arranging process, so that the metal material of the molten metal 6M is held by the gripping member 12. It is a process that is integrally molded with.

As described above, according to the present embodiment, since the molding process is performed using the mold 20 in which the blade edge portion molding surface 24a is formed by the metal foil laminates 23R and 23L, the blade edge portion 11a and the cutting edge 11b are formed on the blade portion 11A. It is possible to form a medical knife 10 in which the gripping member 12 is formed integrally with the support portion 11B. Thereby, the cutting blade 11b can be formed without performing secondary processing such as grinding or polishing on the cutting edge portion 11a.
Moreover, since the holding member 12 can be integrally formed with the support portion 11B and the process of attaching the holding member 12 to the support portion 11B can be omitted, the manufacturing efficiency of the medical knife 10 can be improved.
Further, in the present embodiment, the gripping member 12, in the molding space S _4, since it has an effect of enhancing the thermal insulation against the mold member 20B, as in the medical knife 10, be in the form of a long, downstream it can be filled with the molten metal 6M under high-temperature conditions in the molding space S ₃ on the side.

In the description of the first modification and the second embodiment of the first embodiment, the blade edge portion molding surface is formed by performing the smoothing step after the metal foil laminate is placed on the mold member. The example in the case of smoothing was demonstrated. However, the cutting edge forming surface may be smoothed by smoothing the inner cut end of the metal foil laminate in advance.
For example, the inner cut end 3a or the like of the metal foil 3A or the like may be cut into an inclined surface and then laminated.
Alternatively, the metal foil 3A or the like may be laminated to form a laminated sheet, and then a necessary outer shape may be cut to form a smooth inclined surface during the cutting.

  In the description of the second embodiment, the gripping member arrangement portion has been described as an example in the case where it is provided on the mold member 20B that does not have the metal foil laminated portion 23. You may provide a holding member arrangement | positioning part.

  In the description of the second embodiment, the example in which the gripping member 12 is inserted and disposed in the gripping member placement portion after the mold 20 is assembled has been described. However, the gripping member 12 is the mold member 20B. When assembling, they may be arranged at the same time. In this case, the clearance for inserting the grip member 12 is not required in the grip member arrangement portion.

In the description of the second embodiment, an example in which a pair of plate-shaped gripping members 12 is used as the gripping member has been described. However, the gripping members are not limited to a plate shape, and one pair is used. There is no need.
For example, the grip member 12 may be in close contact with only one side of the support portion 11B. The gripping member 12 may be a tubular member or a rod-shaped member.
In addition, the flow path of the molten metal 6M may be along only a part of the gripping member 12 as long as it can be in close contact with the gripping member 12, and along the entire longitudinal direction of the gripping member 12 as in the second embodiment. It does not have to be.

  In the description of the second embodiment, the molten metal 6M has been described as an example in which the molten metal 6M is solidified along the recessed hole portion 12a penetrating in the thickness direction of the gripping member 12, but is gripped. If the member 12 can be in close contact with sufficient strength, it may be a recessed hole portion that does not penetrate the gripping member 12 in the plate thickness direction. Moreover, you may provide the convex part shape from the holding member 12 side to the support part 11B side. Further, if sufficient adhesion strength is obtained depending on the surface property of the gripping member 12, the gripping member 12 may be configured without the concave hole portion.

  In addition, all the constituent elements described in the above embodiments and modifications can be implemented in appropriate combination within the scope of the technical idea of the present invention.

1 Ophthalmic knife (medical knife)
1A, 11A Blade part 1B, 11B Support end part 1a Tip edge part (blade edge part)
1b Cutting edge (cutting edge)
1g side edge cutting edge (cutting edge)
1h Side edge cutting edge (cutting edge)
2,20 Mold 2A, 2B, 2C, 2D, 20B Mold member 2a, 2b, 2c, 2d, 2e, 2f Mold mating surface 3 Metal foil laminate 3A, 3B, 3C, 3D, 3E, 23La, 23Lb, 23lc, 23Ra, 23Rb, 23Rc Metal foils 3a, 3b, 3c, 3d, 3e Inner cut ends 3a ′, 3b ′, 3c ′, 3d ′, 3e ′ Smooth end surfaces 3f, 23f Laminate lower surface 3g, 23e Laminate upper surface 3h Outer cutting end 4a Tip edge forming surface 4h Side edge cutting edge forming surface 5a, 5b Metal foil arrangement surface 6 Solidified body 6M Molten metal 7 Rolling jig 10 Medical knife (medical knife)
11a Cutting edge portion 11b Cutting edge 11g Engaging portion 12 Holding member 12a Recessed hole portion 12b Engaging projection 20A Blade portion mold portion 20L Side surface portion mold member 20R Side surface portion mold member 20T Top surface portion mold member 20a Holding member arrangement hole (Gripping member placement part)
23 metal foil laminated portion 23L, 23R metal foil laminate 23a, 23b, 23c inclined end face 24a blade edge forming surface 24b side molding surface 24c metallic foil arrangement surface _{P 1} metal foil laminate pressure area _{S 1, S 2, S} 2 ', S ₃ , S ₄ molding space (cavity)

Claims (8)

A method for forming a medical blade using a mold having a cavity for forming a medical blade having a cutting edge part,
Cutting edge to the first die member is at least one of the mold members forming part of the cavity, by placing a metal foil laminate obtained by laminating a plurality of metal foil, forming the shape of the cutting edge A first mold assembly step of forming a partial molding surface and assembling the mold subassembly;
A second mold member is a second mold member so as to press the metal foil laminate with the metal foil laminate sandwiched between the subassemblies assembled in the first mold assembling step . A second mold assembling step for attaching a mold member and assembling the mold having the cavity;
A molding step of molding by injecting a molten metal material into the cavity of the mold assembled in the second mold assembly step;
Equipped with a,
In the second mold assembling step, the metal foil laminate is deformed by being pressed when the second mold member is attached, and the metal foil laminate, the first mold member, and the metal are deformed. method of forming a medical tool the metal foil characterized that you contact the foil laminate and the second mold member, and the metal foil laminate. The first mold assembly process includes:
In order to form the cutting edge part forming surface, after the metal foil laminate is disposed, the method further includes a smoothing step of pressing and smoothing the end of each layer of the metal foil constituting the metal foil laminate. The method for forming a medical blade according to claim 1.   The metal material injected into the cavity in the molding step is a material that becomes amorphous when cooled at a cooling rate equal to or higher than a critical cooling rate of the metal material. A method for forming a medical blade according to claim 1. In any mold member constituting the mold, a gripping member placement portion for placing a gripping member serving as a gripping portion for the medical blade is formed,
A gripping member placement step of placing the gripping member on the gripping member placement portion of the mold assembled in the second die assembly step between the second mold assembly step and the molding step. With
In the molding step,
The metal material is molded integrally with the gripping member by being injected along the surface of the gripping member disposed in the gripping member disposing step. 4. The method for forming a medical blade according to any one of 3 above.   5. The molding of the medical blade according to claim 4, wherein the holding member is provided with a recessed hole portion into which the metal material injected in the molding step flows and is filled with the metal material. Method. The concave hole portion is
The metallic material according to claim 1, wherein the metallic material has a shape that branches from an upstream side to a downstream side in an injection direction of the metallic material, with an inclination at an acute angle with respect to the flow path of the metallic material along the surface. 5. A method for forming a medical blade according to 5. The metal foil laminated in the first mold assembly step is
The method for forming a medical blade according to any one of claims 1 to 6, wherein a metal foil of a material having a higher thermal conductivity is laminated closer to a layer forming the cutting edge of the cutting edge portion. . In the first mold assembly process,
A plurality of the subassemblies are assembled,
In the second mold assembly process,
At least one set of the subassemblies assembled in the first mold assembling step is attached so that the metal foil laminates of the subassemblies are in close contact with each other in the stacking direction, and the metal foil laminates The shape of the said blade edge | tip part is formed by each blade edge | tip part shaping | molding surface of this, The shaping | molding method of the medical blade as described in any one of Claims 1-7 characterized by the above-mentioned.

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