WO1986002868A1 - Surgical cutting instruments - Google Patents

Surgical cutting instruments Download PDF

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Publication number
WO1986002868A1
WO1986002868A1 PCT/GB1985/000513 GB8500513W WO8602868A1 WO 1986002868 A1 WO1986002868 A1 WO 1986002868A1 GB 8500513 W GB8500513 W GB 8500513W WO 8602868 A1 WO8602868 A1 WO 8602868A1
Authority
WO
WIPO (PCT)
Prior art keywords
cutting edge
substrate
titanium
metalloid
titanium alloy
Prior art date
Application number
PCT/GB1985/000513
Other languages
French (fr)
Inventor
Andrew Ivor Abdy Ray
Original Assignee
Micra Limited
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Micra Limited filed Critical Micra Limited
Publication of WO1986002868A1 publication Critical patent/WO1986002868A1/en

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Classifications

    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C8/00Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals
    • C23C8/60Solid state diffusion of only non-metal elements into metallic material surfaces; Chemical surface treatment of metallic material by reaction of the surface with a reactive gas, leaving reaction products of surface material in the coating, e.g. conversion coatings, passivation of metals using solids, e.g. powders, pastes
    • AHUMAN NECESSITIES
    • A61MEDICAL OR VETERINARY SCIENCE; HYGIENE
    • A61BDIAGNOSIS; SURGERY; IDENTIFICATION
    • A61B17/00Surgical instruments, devices or methods, e.g. tourniquets
    • A61B17/32Surgical cutting instruments
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B23MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
    • B23PMETAL-WORKING NOT OTHERWISE PROVIDED FOR; COMBINED OPERATIONS; UNIVERSAL MACHINE TOOLS
    • B23P15/00Making specific metal objects by operations not covered by a single other subclass or a group in this subclass
    • B23P15/28Making specific metal objects by operations not covered by a single other subclass or a group in this subclass cutting tools
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C26/00Coating not provided for in groups C23C2/00 - C23C24/00
    • C23C26/02Coating not provided for in groups C23C2/00 - C23C24/00 applying molten material to the substrate

Definitions

  • the present invention relates to surgical cutting instruments and their methods of manufacture.
  • Surgical cutting instruments have been proposed with hardened cutting edges.
  • Such instruments are difficult to fabricate and often the materials used for the blade and for hardening the blade are unsuitable for use in surgery because they either can contaminate human tissue or become themselves the subject of a reaction with the human body fluids .
  • Titanium has been found to be a highly suitable material for surgical instruments. Titanium has a very high strength to weight ratio, and is generally inert has far as surgical processes are concerned. Titanium is hard and so provides a durable cutting edge. Nevertheless, the period for which titanium remains sharp for surgical purposes (where standards for sharpness are extremely high) is still relatively short.
  • the object of the present invention is to provide a surgical cutting implement of titanium having an improved cutting edge.
  • a surgical cutting implement of titanium or a titanium alloy having a- cutting edge which is infused with at least one metalloid and treated to render the cutting edge amorphous.
  • a method of hardening a surgical cutting instrument of titanium or a titanium alloy comprises the steps of depositing a layer of metalloid on the cutting edge, heating the layer of metalloid and the immediately adjacent titanium or titanium alloy substrate to melting point, to effect an infusion of the metalloid into the substrate and rapidly cooling the cutting edge to render at least part of the substrate infused with the metalloid, amorphous.
  • a method of making a surgical cutting implement comprising the steps of forming a cutting edge substrate of titanium or titanium alloy, coating the cutting edge substrate with a metalloid layer, placing the coated cutting edge substrate in a cold environment, effecting local heating of the cutting edge substrate sufficient to allow local infusion of the metalloid into the substrate, displacing the locality of the heating progressively to cover the whole of the cutting edge substrate, the cold environment having such a low .temperature that following lo'cal heating, the cutting edge substrate is cooled sufficiently quickly for an amorphous outer layer to form, and removing part of the amorphous outer layer to provide a sharp edge for the treated substrate.
  • the cutting edge is lapped to remove a portion of the infused titanium or titanium alloy and to leave a sharp edge.
  • the depth to which the infused titanium or titanium alloy is removed is selected to be that depth at which the infused titanium or titanium alloy has reached its maximum hardness.
  • the method of heating and cooling the cutting edge is by submerging the cutting edge in a liquid coolant and scanning the blade with a laser.
  • metalloids are selected from the group consisting of Phosphorous, Boron, Carbon, Silicon and Germanium.
  • Figure 1 is a section through a titanium knife blade onto which a layer of metalloid has been deposited;
  • the surgical cutting instrument to be described is of titanium or a titanium alloy, the preferred material being commercially available, 318 Titanium Alloy.
  • the cutting edge of the titanium or titanium alloy is hardened by a process to be described hereinafter.
  • the cutting edge of the instrument before being processed will be referred to as the substrate.
  • the layer 2 of metalloid and the immediately adjacent portion of the substrate 4 are heated to melting point. As a result, the metalloid tends to become infused into the upper portion of the substrate to form a composite titanium or titanium alloy/metalloid layer 6 (see Figure 2) . '
  • the layers 3 and 6 are then rapidly cooled, for example by subjecting them to an environment having a temperature of less than -150°C. Because of the thickness of the composite layer, that part of the layer nearest the upper surface of the cutting edge will cool faster than that part of the composite layer which lies furthest from the upper surface. As a result, the composite layer upon cooling will progress from an upper region which is amorphous to a lower region which is crystalline, the crystalline structure becoming smaller with distance from the outer surface of the cutting edge.
  • the heating and cooling process is carried out by submerging the cutting edge of the instrument in a bath of liquid coolant (for example, liquid nitrogen) and then progressively scanning the cutting edge with a laser beam. In this way the cutting edge is progressively processed. The point on the cutting edge where the laser beam impinges becomes molten, and, and as soon as the beam moves on, the liquid coolant acts to effect rapid cooling. The result of this process, as shown in
  • the cutting edge is then lapped or otherwise treated to remove the remnants of the metalloid layer 2 and part of the composite layer to a depth in the amorphous region where the amorphous region has reached its maximum hardness (see Figure 3).
  • This depth can be readily determined experimentally by processing a test piece of similar material simultaneously with the cutting edge and then removing the outer surface of the test piece in small steps, making a hardness measurement after each step.
  • the lapping action is also conducted to render the cutting edge sharp.
  • a tank 26 of liquid nitrogen has a discharge spout 28 for discharging liquid nitrogen into the bath 14 to maintain the level of the liquid nitrogen in the bath 14 constant.
  • This function may be performed manually by an operator or may be automated in a manner well known in the art.
  • the bath 14 is filled with liquid nitrogen to a predetermined level and the *
  • the workpiece is subsequently removed from the bath 14 and lapped to remove any residual metalloid and to provide a sharp cutting edge. It will be appreciated that instead of heating and cooling with a laser and liquid nitrogen, other methods may be used to effect surface heating of the cutting edge followed by rapid quenching.

Abstract

A surgical cutting instrument is formed by producing a cutting edge substrate or workpiece (10) of titanium or a titanium alloy. The substrate (10) is coated with a metalloid layer (12) and the whole is submerged in a bath (14) of liquid nitrogen (16). A laser (22) provides a beam (24) which scans the workpiece (10) and locally heats the surface sufficiently for the surface to melt and for the metalloid to diffuse into the substrate. As the beam passes, the surface is rapidly cooled so that an amorphous layer is formed. The treated substrate is lapped to remove any residual metalloid and to sharpen the cutting edge.

Description

SURGICAL CUTTING INSTRUMENTS
The present invention relates to surgical cutting instruments and their methods of manufacture. Surgical cutting instruments have been proposed with hardened cutting edges. Such instruments are difficult to fabricate and often the materials used for the blade and for hardening the blade are unsuitable for use in surgery because they either can contaminate human tissue or become themselves the subject of a reaction with the human body fluids .
Titanium has been found to be a highly suitable material for surgical instruments. Titanium has a very high strength to weight ratio, and is generally inert has far as surgical processes are concerned. Titanium is hard and so provides a durable cutting edge. Nevertheless, the period for which titanium remains sharp for surgical purposes (where standards for sharpness are extremely high) is still relatively short.
The object of the present invention is to provide a surgical cutting implement of titanium having an improved cutting edge. According to the present invention there is provided a surgical cutting implement of titanium or a titanium alloy having a- cutting edge which is infused with at least one metalloid and treated to render the cutting edge amorphous. According to the present invention there is further provided a method of hardening a surgical cutting instrument of titanium or a titanium alloy comprises the steps of depositing a layer of metalloid on the cutting edge, heating the layer of metalloid and the immediately adjacent titanium or titanium alloy substrate to melting point, to effect an infusion of the metalloid into the substrate and rapidly cooling the cutting edge to render at least part of the substrate infused with the metalloid, amorphous.
According to the present invention there is further provided a method of making a surgical cutting implement comprising the steps of forming a cutting edge substrate of titanium or titanium alloy, coating the cutting edge substrate with a metalloid layer, placing the coated cutting edge substrate in a cold environment, effecting local heating of the cutting edge substrate sufficient to allow local infusion of the metalloid into the substrate, displacing the locality of the heating progressively to cover the whole of the cutting edge substrate, the cold environment having such a low .temperature that following lo'cal heating, the cutting edge substrate is cooled sufficiently quickly for an amorphous outer layer to form, and removing part of the amorphous outer layer to provide a sharp edge for the treated substrate.
Preferably the cutting edge is lapped to remove a portion of the infused titanium or titanium alloy and to leave a sharp edge.
The depth to which the infused titanium or titanium alloy is removed is selected to be that depth at which the infused titanium or titanium alloy has reached its maximum hardness. Advantageously the method of heating and cooling the cutting edge is by submerging the cutting edge in a liquid coolant and scanning the blade with a laser. - *
Advantageously the metalloids are selected from the group consisting of Phosphorous, Boron, Carbon, Silicon and Germanium. A surgical cutting instrument and its method of manufacture will now be described, by way of example, with reference to the accompanying diagrammatic drawings in which: Figure 1 is a section through a titanium knife blade onto which a layer of metalloid has been deposited;
Figure 2 is a section through the knife blade of Figure 1 after heating and subsequent cooling; and
Figure 3 is a section through the knife blade of Figure 1 after lapping.
The surgical cutting instrument to be described is of titanium or a titanium alloy, the preferred material being commercially available, 318 Titanium Alloy. The cutting edge of the titanium or titanium alloy is hardened by a process to be described hereinafter. In the drawings, the cutting edge of the instrument before being processed will be referred to as the substrate.
As shown in Figure 1 , the substrate 4 is coated with a layer 2 of metalloid. The term metalloid as used herein refers to that class of material which is non-metallic but which can have the properties of a metal for example Arsenic, Silicon,
Boron, Tellurium, Antimony, Bismuth, Phosphorous, and Germanium.
The layer 2 of metalloid and the immediately adjacent portion of the substrate 4 are heated to melting point. As a result, the metalloid tends to become infused into the upper portion of the substrate to form a composite titanium or titanium alloy/metalloid layer 6 (see Figure 2) . '
The layers 3 and 6 are then rapidly cooled, for example by subjecting them to an environment having a temperature of less than -150°C. Because of the thickness of the composite layer, that part of the layer nearest the upper surface of the cutting edge will cool faster than that part of the composite layer which lies furthest from the upper surface. As a result, the composite layer upon cooling will progress from an upper region which is amorphous to a lower region which is crystalline, the crystalline structure becoming smaller with distance from the outer surface of the cutting edge.
The heating and cooling process is carried out by submerging the cutting edge of the instrument in a bath of liquid coolant (for example, liquid nitrogen) and then progressively scanning the cutting edge with a laser beam. In this way the cutting edge is progressively processed. The point on the cutting edge where the laser beam impinges becomes molten, and, and as soon as the beam moves on, the liquid coolant acts to effect rapid cooling. The result of this process, as shown in
Figure 2, is a three part structure consisting of the remnants of a layer of metalloid 2, a composite layer 6 which changes progressively from an amorphous structure to a large crystalline structure and then to a small crystalline structure, and the original substrate layer of unchanged titanium or titanium alloy.
The cutting edge is then lapped or otherwise treated to remove the remnants of the metalloid layer 2 and part of the composite layer to a depth in the amorphous region where the amorphous region has reached its maximum hardness (see Figure 3). This depth can be readily determined experimentally by processing a test piece of similar material simultaneously with the cutting edge and then removing the outer surface of the test piece in small steps, making a hardness measurement after each step.
The lapping action is also conducted to render the cutting edge sharp.
The processed blade has a significantly improved hardness over the original titanium or titanium alloy blade so that its life span is extended dramatically. Figure 4 shows apparatus for heating and cooling a titanium substrate workpiece 10 coated with a metalloid layer 12. As shown a thermally insulated bath 14 is filled with liquid nitrogen 16. A support structure 18 mounted on the floor of the bath is provided with an array of pins 20 to support the workpiece 10 so that its upper surface lies just below the surface of the liquid nitrogen and its underside is for the most part exposed to direct contact with" the liquid nitrogen 16. A laser assembly 22 mounted above the bath 14 projects a laser beam 24 on to the upper surface of the workpiece 10. The assembly includes beam deflection means (not shown) for causing the beam 24 to perform a full scan of the surface area of the workpiece 10. The deflector means is advantageously an optical scanning arrangement of the type well known in the ar .
A tank 26 of liquid nitrogen has a discharge spout 28 for discharging liquid nitrogen into the bath 14 to maintain the level of the liquid nitrogen in the bath 14 constant. This function may be performed manually by an operator or may be automated in a manner well known in the art.
In operation the bath 14 is filled with liquid nitrogen to a predetermined level and the *
-6- workpiece is lowered into the bath 14 until it rests on the pins 20. The laser assembly 22 is energised and actuated to cause the beam 24 o progressively scan the workpiece. The heating and rapid quenching of the surface of the workpiece produces a structure as described with reference to Figure 2.
The workpiece is subsequently removed from the bath 14 and lapped to remove any residual metalloid and to provide a sharp cutting edge. It will be appreciated that instead of heating and cooling with a laser and liquid nitrogen, other methods may be used to effect surface heating of the cutting edge followed by rapid quenching.

Claims

1. A surgical cutting implement of titanium or a titanium alloy having a cutting edge which is infused with at least one metalloid and treated to render the cutting edge amorphous.
2. A method of hardening a surgical cutting instrument of titanium or a titanium alloy comprises the steps of depositing a layer of metalloid on the cutting edge, heating the layer of metalloid and the immediately adjacent titanium or titanium alloy substrate to melting point, to effect an infusion of the metalloid into the substrate and rapidly cooling the cutting edge to render at least part of the substrate infused with the metalloid, amorphous. 3- A method according to Claim 2 including the step of lapping the cutting edge to remove a portion of t'*- infused titanium or titanium alloy and to leave a sharp edge.
4- A method according to Claim 3 wherein the lapping step removes the infused titanium or titanium alloy to that depth at which the infused titanium or titanium alloy is substantially at maximum hardness.
5 - A method according to any of Claims 2 to 4 wherein the heating and cooling of the cutting edge is effected by submerging the cutting edge in a liquid coolant and scanning the blade with a laser. 6. A method of making a surgical cutting implement comprising the steps of forming a cutting edge substrate of titanium or titanium alloy, coating the cutting edge substrate with a metalloid layer, placing the coated cutting edge substrate in a cold environment, effecting local heating of the cutting edge substrate sufficient to allow local infusion of the metalloid into the substrate, displacing the locality of the heating progressively to cover the whole of the cutting edge substrate, the cold environment having such a low temperature that following local heating, the cutting edge substrate is cooled sufficiently quickly for an amorphous outer layer to form, and removing part of the amorphous outer layer to provide a sharp edge for the treated substrate .
7- A method according to Claim 6 wherein the step of effecting local heating is provided by exposing the coated substrate to a laser beam.
8. A method according to Claim 6 or Claim 7 wherein the temperature of the cold environment is less than -150°C. S - A method according to any one of Claims 6 to 8 wherein the cold environment comprises a bath of liquid nitrogen.
10. A method according to any one of Claims 6 to 9 wherein removal of the amorphous outer layer is effected by lapping. 11. An implement or a method according to any preceding claim wherein the metalloid are selected from the group consisting of Phosphorous,Boron, Carbon,. Silicon and Germanium. 12. A surgical cutting instrument produced by the method of any one of Claims 2 to 11.
PCT/GB1985/000513 1984-11-09 1985-11-11 Surgical cutting instruments WO1986002868A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
GB8428410 1984-11-09
GB848428410A GB8428410D0 (en) 1984-11-09 1984-11-09 Surgical cutting instruments

Publications (1)

Publication Number Publication Date
WO1986002868A1 true WO1986002868A1 (en) 1986-05-22

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EP (1) EP0201555A1 (en)
GB (1) GB8428410D0 (en)
WO (1) WO1986002868A1 (en)

Cited By (8)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0304488A1 (en) * 1987-03-11 1989-03-01 NAUCHNO-ISSLEDOVATELSKY INSTITUT TEKHNOLOGII AVTOMOBILNOI PROMYSHLENNOSTI (NIITavtoprom) Method for obtaining coatings on parts
WO1991005072A1 (en) * 1989-10-07 1991-04-18 The University Of Birmingham Method of modifying the surface of a substrate
US5317938A (en) * 1992-01-16 1994-06-07 Duke University Method for making microstructural surgical instruments
WO1995009932A1 (en) * 1993-10-06 1995-04-13 The University Of Birmingham Titanium alloy products and methods for their production
EP1199055A1 (en) 2000-10-16 2002-04-24 Gebauer GmbH Blade with amorphous cutting edge
DE10051215A1 (en) * 2000-10-16 2002-05-08 Gebauer Gmbh Blade with amorphous cutting edge
WO2004052254A1 (en) 2002-12-10 2004-06-24 Sightrate B.V. Disposable separator for separating the epithelium layer from the cornea of an eye
CN109759549A (en) * 2019-01-31 2019-05-17 东莞宜安科技股份有限公司 A kind of amorphous alloy process units

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN109267063A (en) * 2018-11-06 2019-01-25 成都飞机工业(集团)有限责任公司 A method of titanium alloy is repaired based on laser melting coating and forges beam surface defect

Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3940293A (en) * 1972-12-20 1976-02-24 Allied Chemical Corporation Method of producing amorphous cutting blades
FR2341665A1 (en) * 1976-02-17 1977-09-16 United Technologies Corp METAL ARTICLES WITH COMPOSITE MICROSTRUCTURE
FR2371520A1 (en) * 1976-09-13 1978-06-16 Ford France SURFACE ALLOY AND THERMAL TREATMENT PROCESS
US4212900A (en) * 1978-08-14 1980-07-15 Serlin Richard A Surface alloying method and apparatus using high energy beam
DE3219071A1 (en) * 1982-05-21 1983-11-24 Udo Dr. 4300 Essen König Process for plating titanium with a hard layer
EP0119714A2 (en) * 1983-02-15 1984-09-26 MICRA Limited Cutting and piercing devices
WO1984004899A1 (en) * 1983-06-10 1984-12-20 Dresser Ind Wear-resistant amorphous materials and articles, and process for preparation thereof

Patent Citations (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US3940293A (en) * 1972-12-20 1976-02-24 Allied Chemical Corporation Method of producing amorphous cutting blades
FR2341665A1 (en) * 1976-02-17 1977-09-16 United Technologies Corp METAL ARTICLES WITH COMPOSITE MICROSTRUCTURE
FR2371520A1 (en) * 1976-09-13 1978-06-16 Ford France SURFACE ALLOY AND THERMAL TREATMENT PROCESS
US4212900A (en) * 1978-08-14 1980-07-15 Serlin Richard A Surface alloying method and apparatus using high energy beam
DE3219071A1 (en) * 1982-05-21 1983-11-24 Udo Dr. 4300 Essen König Process for plating titanium with a hard layer
EP0119714A2 (en) * 1983-02-15 1984-09-26 MICRA Limited Cutting and piercing devices
WO1984004899A1 (en) * 1983-06-10 1984-12-20 Dresser Ind Wear-resistant amorphous materials and articles, and process for preparation thereof

Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
EP0304488A1 (en) * 1987-03-11 1989-03-01 NAUCHNO-ISSLEDOVATELSKY INSTITUT TEKHNOLOGII AVTOMOBILNOI PROMYSHLENNOSTI (NIITavtoprom) Method for obtaining coatings on parts
EP0304488A4 (en) * 1987-03-11 1989-09-26 Nii Tekh Avtomobil Promy Method for obtaining coatings on parts.
WO1991005072A1 (en) * 1989-10-07 1991-04-18 The University Of Birmingham Method of modifying the surface of a substrate
US5317938A (en) * 1992-01-16 1994-06-07 Duke University Method for making microstructural surgical instruments
WO1995009932A1 (en) * 1993-10-06 1995-04-13 The University Of Birmingham Titanium alloy products and methods for their production
US5792289A (en) * 1993-10-06 1998-08-11 The University Of Birmingham Titanium alloy products and methods for their production
EP1199055A1 (en) 2000-10-16 2002-04-24 Gebauer GmbH Blade with amorphous cutting edge
DE10051215A1 (en) * 2000-10-16 2002-05-08 Gebauer Gmbh Blade with amorphous cutting edge
WO2004052254A1 (en) 2002-12-10 2004-06-24 Sightrate B.V. Disposable separator for separating the epithelium layer from the cornea of an eye
CN109759549A (en) * 2019-01-31 2019-05-17 东莞宜安科技股份有限公司 A kind of amorphous alloy process units
CN109759549B (en) * 2019-01-31 2020-09-25 东莞宜安科技股份有限公司 Amorphous alloy apparatus for producing

Also Published As

Publication number Publication date
EP0201555A1 (en) 1986-11-20
GB8428410D0 (en) 1984-12-19

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