U.S. patent application number 13/525884 was filed with the patent office on 2012-10-11 for methods of altering surgical fiber.
This patent application is currently assigned to Tyco Healthcare Group LP. Invention is credited to Matthew D. Cohen, Nicholas Maiorino, Michael Primavera.
Application Number | 20120255157 13/525884 |
Document ID | / |
Family ID | 40938110 |
Filed Date | 2012-10-11 |
United States Patent
Application |
20120255157 |
Kind Code |
A1 |
Maiorino; Nicholas ; et
al. |
October 11, 2012 |
Methods of Altering Surgical Fiber
Abstract
The present disclosure relates to methods of altering a surgical
fiber by irradiating the surgical fiber with an energy beam such
that material is removed therefrom.
Inventors: |
Maiorino; Nicholas;
(Branford, CT) ; Primavera; Michael; (Orange,
CT) ; Cohen; Matthew D.; (Berlin, CT) |
Assignee: |
Tyco Healthcare Group LP
Mansfield
MA
|
Family ID: |
40938110 |
Appl. No.: |
13/525884 |
Filed: |
June 18, 2012 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
12352956 |
Jan 13, 2009 |
8222564 |
|
|
13525884 |
|
|
|
|
61028205 |
Feb 13, 2008 |
|
|
|
Current U.S.
Class: |
29/505 ;
29/428 |
Current CPC
Class: |
A61B 17/06195 20130101;
A61B 17/06004 20130101; A61B 2017/00526 20130101; Y10T 29/49826
20150115; Y10T 29/49908 20150115; A61B 2017/06033 20130101; D06M
10/005 20130101; A61B 17/06166 20130101 |
Class at
Publication: |
29/505 ;
29/428 |
International
Class: |
B23K 26/42 20060101
B23K026/42; B23P 15/00 20060101 B23P015/00 |
Claims
1. A method of manufacturing and assembling a surgical needle and a
surgical fiber, comprising: directing at least one beam emitted
from an irradiating device at the surgical fiber for a time, and
with an intensity, sufficient to remove material from the surgical
fiber such that a reduced portion is formed; inserting the reduced
portion of the surgical fiber into an opening in a proximal end of
the surgical needle; and coupling the surgical needle and the
surgical fiber together such that the reduced portion of the
surgical fiber is secured within the opening in the proximal end of
the surgical needle.
2. The method of claim 1, wherein coupling the surgical needle and
the surgical fiber together includes coining the surgical
needle.
3. The method of claim 1, wherein coupling the surgical needle and
the surgical fiber together includes crimping the surgical
needle.
4. The method of claim 1, wherein coupling the surgical needle and
the surgical fiber together includes positioning an adhesive
between the reduced portion of the surgical fiber and the opening
in the proximal end of the surgical needle.
5. The method of claim 1 further comprising redirecting the at
least one beam with a curved reflector such that the at least one
beam is incident upon the surgical fiber from a plurality of
angles.
6. The method of claim 5 further including rotating the surgical
fiber.
7. The method of claim 1, wherein directing the at least one beam
includes directing a plurality of beams emitted from a plurality of
irradiating devices at the surgical fiber.
8. A method of manufacturing and assembling a surgical needle and a
surgical fiber, comprising: altering the surgical fiber by
directing at least one beam emitted from an irradiating device onto
the surgical fiber to create a reduced portion having a non-uniform
topography; inserting the reduced portion of the surgical fiber
into an opening in a proximal end of the surgical needle; and
coupling the surgical needle and the surgical fiber together such
that the reduced portion of the surgical fiber is secured within
the opening in the proximal end of the surgical needle.
9. The method of claim 8, wherein altering the surgical fiber
includes forming the reduced portion to include a thread.
10. The method of claim 8, wherein altering the surgical fiber
includes forming the reduced portion to include a plurality of
ribs.
11. The method of claim 8, wherein altering the surgical fiber
includes forming the reduced portion to include a plurality of
barbs.
12. The method of claim 8, wherein coupling the surgical needle and
the surgical fiber together includes coining the surgical
needle.
13. The method of claim 8, wherein coupling the surgical needle and
the surgical fiber together includes crimping the surgical
needle.
14. The method of claim 8, wherein coupling the surgical needle and
the surgical fiber together includes positioning an adhesive
between the reduced portion of the surgical fiber and the opening
in the proximal end of the surgical needle.
15. A method of manufacturing and assembling a surgical needle and
a surgical fiber, comprising: directing at least one beam emitted
from an irradiating device along a longitudinal axis defined by the
surgical fiber such that the material is removed from an internal
region of the surgical fiber to thereby form a cavity; applying a
force to the surgical fiber to thereby reduce an internal dimension
of the cavity, and create a reduced portion of the surgical fiber;
inserting the reduced portion of the surgical fiber into an opening
in a proximal end of the surgical needle; and coupling the surgical
needle and the surgical fiber together such that the reduced
portion of the surgical fiber is secured within the opening in the
proximal end of the surgical needle.
16. The method of claim 15, wherein coupling the surgical needle
and the surgical fiber together includes coining the surgical
needle.
17. The method of claim 15, wherein coupling the surgical needle
and the surgical fiber together includes crimping the surgical
needle.
18. The method of claim 15, wherein coupling the surgical needle
and the surgical fiber together includes positioning an adhesive
between the reduced portion of the surgical fiber and the opening
in the proximal end of the surgical needle.
19. The method of claim 15 further comprising redirecting the at
least one beam with a curved reflector such that the at least one
beam is incident upon the surgical fiber from a plurality of
angles.
20. The method of claim 19 further including rotating the surgical
fiber.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent
application Ser. No. 12/352,956, filed Jan. 13, 2009, which claims
the benefit of, and priority to, U.S. Provisional patent
application Ser. No. 61/028,205, filed Feb. 13, 2008, now expired,
the entire content of each of the applications identified above
being incorporated by reference herein.
BACKGROUND
[0002] 1. Technical Field
[0003] The present disclosure relates to a method of altering a
surgical fiber. In particular, the present disclosure relates to
methods of removing at least a portion of the surgical fiber to
facilitate the coupling thereof with a surgical needle.
[0004] 2. Background of the Related Art
[0005] Surgical fibers have many uses in contemporary medical
practice. These include joining skin, internal organs, blood
vessels, and other tissues of the body together after they have
been severed by injury or surgery. To serve this end, the surgical
fiber is passed through the tissue to be joined using a surgical
needle or other such surgical device. To facilitate coupling of the
surgical fiber with the surgical needle, it is often necessary to
alter the surgical fiber.
[0006] Conventionally, the surgical fiber is altered through the
use of mechanical machining methods, such as cutting, grinding,
and/or milling. However, mechanical machining methods are generally
slow, and over time, the devices employed in these methods wear,
creating variations in accuracy and precision of the finished
product.
[0007] Accordingly, a need exists in the art for a method of
altering surgical fibers that addresses the deficiencies of
mechanical machining methods.
SUMMARY
[0008] In one aspect of the present disclosure, a method of
altering a surgical fiber is disclosed. The method comprises the
steps of providing the surgical fiber, at least a portion of which
defines a first axis, providing an irradiating device for emitting
at least one beam, and directing the at least one beam at the
surgical fiber for a time and with an intensity sufficient to
remove material therefrom such that a reduced portion is formed
that is configured and dimensioned for coupling with a surgical
needle.
[0009] In one embodiment, the irradiating device emits the at least
one beam along a second axis that extends in transverse relation to
the first axis. It is further contemplated that in one embodiment,
the method may further comprise the step of providing a curved
reflector for redirecting the at least one beam such that it is
simultaneously or sequentially incident upon the surgical fiber
from a plurality of angles.
[0010] The step of providing the surgical fiber may comprise
providing a holder for releasably engaging the surgical fiber
during the irradiation thereof. The holder may be fixed with
respect to the curved reflector. The irradiating device may be
fixed with respect to the holder. The holder may be configured to
rotate the surgical fiber about the first axis. The holder and the
curved reflector may be configured for relative movement
therebetween. The irradiating device and the holder may be
configured for relative movement therebetween, or the irradiating
device may be configured to move along the first axis.
[0011] The at least one beam may be directed at the surgical fiber
such that the reduced portion defines a substantially non-uniform
topography to facilitate anchoring of the reduced portion with the
surgical needle.
[0012] In an alternate aspect of the present disclosure, the step
of directing the at least one beam at the surgical fiber may also
include directing the at least one beam substantially along the
first axis such that the material is removed from an internal
region of the surgical fiber to thereby form a cavity. Subsequent
thereto, a force may be applied to the surgical fiber to thereby
reduce its initial outer dimension.
[0013] In yet another aspect of the present disclosure, a method of
altering a surgical fiber to facilitate the coupling thereof with
the surgical needle is disclosed. The method comprises the steps of
providing a surgical fiber, at least a portion of which extends
along a first axis, providing a plurality of irradiating devices
for emitting at least one beam, and directing the at least one beam
at said surgical fiber for a time and with an intensity sufficient
to remove material therefrom
[0014] In one embodiment, the irradiating devices are oriented in
spaced apart relation along the first axis defined by the surgical
fiber.
[0015] The plurality of irradiating devices and the holder may be
configured for relative movement therebetween. The plurality of
irradiating devices may be fixed in relation to the holder. The
holder may be configured to rotate the surgical fiber about the
first axis, or the plurality of irradiating devices may be
configured to move along the first axis.
[0016] These and other features of the methods disclosed herein
will become more readily apparent to those skilled in the art from
the following detailed description of various embodiments of the
present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Various embodiments of the present disclosure are described
hereinbelow with references to the drawings, wherein:
[0018] FIG. 1 is a perspective view of an exemplary surgical fiber
removed from a surgical needle;
[0019] FIGS. 2A-2B are side perspective views of alternate
embodiments of the surgical fiber of FIG. 1;
[0020] FIG. 3A is a perspective view of an irradiating device, a
curved reflector, and a holder for use in a method of altering the
surgical fiber of FIG. 1;
[0021] FIG. 3B is a top view of the irradiating device, the curved
reflector, and the holder of FIG. 3A; and
[0022] FIG. 4A is a side perspective view of the irradiating device
for use in an alternate method of altering the surgical fiber of
FIG. 1;
[0023] FIG. 4B is a side perspective view of the surgical fiber of
FIG. 4A subsequent to alteration;
[0024] FIG. 4C is a side perspective view of the surgical fiber of
FIG. 4B in which an outer dimension thereof is reduced through the
application of an external force subsequent to alteration;
[0025] FIG. 4D is a side perspective view of the irradiating device
for use in another method of altering the surgical fiber of FIG.
1;
[0026] FIG. 4E is a side perspective view of the surgical fiber of
FIG. 4D subsequent to alteration; and
[0027] FIG. 5 is a perspective view of a plurality of irradiating
devices and a holder for use in yet another method of altering the
surgical fiber of FIG. 1.
DESCRIPTION OF THE EMBODIMENTS
[0028] In the drawings and in the description which follows, in
which like references numerals identify similar or identical
elements, the term "surgical fiber" should be understood to refer
to any surgical grade suture, filament, tape, or the like suitable
for the intended purpose of joining severed tissue.
[0029] With reference now to FIG. 1, an exemplary surgical needle
100 and a surgical fiber 200 are illustrated. Surgical needle 100
may be formed of any suitable biocompatible material, including but
not limited to stainless steel, and includes respective first and
second ends 102, 104 with a shaft 106 extending therebetween that
may be curved, as shown, or substantially straight. Further details
regarding surgical needle 100, as well as methods of altering
surgical needles and attaching surgical needles to surgical fibers,
are disclosed in U.S. Pat. Nos. 5,383,902, 5,479,980, 5,507,798,
5,568,746, 5,693,071, 5,747,770, 5,865,836, 5,941,899, and
5,968,076, the entire contents of which are incorporated by
reference herein.
[0030] First end 102 may exhibit any configuration suitable for
penetration of tissue, and may be substantially incisive, as shown,
or substantially blunt.
[0031] Second end 104 includes receiving structure 108. Receiving
structure 108 defines an internal dimension "DN" sized to receive a
first end 202 of surgical fiber 200, and corresponds in
configuration thereto, such that surgical fiber 200 and surgical
needle 100 may be coupled together.
[0032] Surgical fiber 200 may be formed of any suitable
biocompatible material, including but not being limited to
polypropylene, polyester, nylon, or stainless steel, and extends at
least partially along an axis "A". Initially, in an unaltered
condition, surgical fiber 200 defines an outer dimension "D.sub.1"
measured along an axis "B" that is orthogonal in relation to the
axis "A" along which surgical fiber 200 extends. The initial outer
dimension "D.sub.1" of surgical fiber 200 is substantially larger
than the internal dimension "D.sub.N" of the receiving structure
108, thereby prohibiting the coupling of surgical fiber 200 and
surgical needle 100. However, the initial outer dimension "D.sub.1"
of surgical fiber 200 may be reduced, through the process discussed
herein below, such that a reduced portion 204 is defined. The
reduced portion 204 defines a second outer dimension "D.sub.2" that
facilitates the insertion of first end 202 of surgical fiber 200
into the receiving structure 108 of surgical needle 100 such that
surgical fiber 200 and surgical needle 100 may be coupled together
by coining, crimping, or through the use of adhesives, as is known
in the art.
[0033] As illustrated in FIG. 1, the reduced portion 204 may define
a substantially uniform topography. Alternatively, as seen in FIGS.
2A-2C, the reduced portion 204 may define a substantially
non-uniform topography, e.g., inclusive of threads 206, ribs 208,
or barbs 210 to assist in the anchoring of the reduced portion 204
within the receiving structure 108.
[0034] Referring now to FIGS. 1 and 3A-3B, a method of reducing the
initial outer dimension "D.sub.1" of surgical fiber 200 will be
discussed. The disclosed method employs an irradiating device 300
to effectuate localized ablation of the material comprising
surgical fiber 200. Irradiating device 300 generates and emits at
least one beam 302 that is incident upon surgical fiber 200 to
cause a reduction in its initial outer dimension "D.sub.1" and
thereby define the reduced portion 204 discussed above. While the
present disclosure contemplates the use of an irradiating device
300 that emits a laser beam, any irradiating device 300 adapted to
emit an energy beam capable of accomplishing the functional aspects
of the presently disclosed method may be employed.
[0035] Various parameters of beam 302, including but not being
limited to the scan rate, peak power, pulse repetition rate, spot
size, energy per pulse, pulse width, and wavelength, can
manipulated dependent upon the material constituting surgical fiber
200 so as to control the removal of material from the suture. For
example, the laser removal of polymeric materials is often
performed with lasers that generate pulsed beams at wavelengths of
248 nm, 193 nm, or less, as shorter wavelengths and pulses reduce
any excess heat that may be generated which could otherwise damage
the workpiece, i.e. the surgical fiber 200.
[0036] During alteration, the surgical fiber 200 is maintained
within a holder 304 configured for the releasable engagement
thereof. A portion of the beams 302 emitted by irradiating device
300 are directly incident upon surgical fiber 200, whereas a
remaining portion of beam 302 are directed past surgical fiber 200.
In one embodiment, the portion of beams 302 directed past surgical
fiber 200 are redirected by a curved reflector 306 such that the
beams 302 emitted by irradiating device 300 are incident upon
surgical fiber 200 from 3600, thereby facilitating the uniform
irradiation of surgical fiber 200. While FIGS. 3A and 3B illustrate
beams 302 which are emitted from irradiating device 300 along axis
"B", which is orthogonal to the axis "A" defined by surgical fiber
200, irradiating device 300 may be configured so as to emit beams
302 along any suitable transverse axis which intersects axis "A",
or along axis "A" itself. Curved reflector 306 may define any arc
length 308 suitable for this intended purpose. Beams 302 may be
directed simultaneously or sequentially at surgical fiber 200.
[0037] The curved reflector 306 and the irradiating device 300 may
each remain stationary during the irradiation of surgical fiber
200, in which instance, the holder 304 may be adapted to rotate the
surgical fiber 200, in the direction indicated by arrows 1 and 2,
about the axis "A" defined by thereby to further ensure uniform
irradiation. Holder 304 may also be adapted to translate along the
axis "A" in the direction of arrows 3 and 4 to selectively define
an axial dimension "L" of the reduced portion 204. In an alternate
embodiment, the holder 304 may remain stationary, and irradiating
device 300 and reflector 306 may be configured to effect relative
movement with respect to holder 304 to assure uniform irradiation
of surgical fiber 200. As an example, either or both of the
irradiating device 300 and the reflector 306 may be configured to
revolve about the holder 304 in the directions indicated by arrows
5 and 6, as seen in FIG. 3B. The irradiating device 300 and the
reflector 306 may also be configured to translate along the axis
"A" in the direction of arrows 3 and 4 to thereby selectively
define the axial dimension "L" of the reduced portion 204.
[0038] With reference now to FIGS. 4A-4B, in an alternate aspect of
the present disclosure, the beams 302 generated by irradiating
device 300 may be incident upon surgical fiber 200 substantially
along the axis "A" defined thereby, as discussed previously. Upon
contacting surgical fiber 200, the beams 302 will remove material
from an internal region 212 thereof defined beneath an outer
surface 214 of surgical fiber 200 and form a cavity 216. The beams
302 may be of sufficient intensity, and may be incident upon
internal region 212 for a sufficient amount of time, such that upon
the removal of material from internal region 212, the outer surface
214 of surgical fiber 200 will collapse inwardly upon cavity 216,
thereby causing a reduction in the initial outer dimension
"D.sub.1" of surgical fiber 200 and defining the reduced portion
204 discussed above with respect to FIG. 1. However, the present
disclosure also contemplates that the outer surface 214 of surgical
fiber 200 may not collapse inwardly upon the removal of material
from internal region 212, in which event the initial outer
dimension "D.sub.1" of surgical fiber 200 will be reduced, and the
reduced portion 204 defined (FIG. 4B), through the application of
an external force "F" to the outer surface 214 of surgical fiber
200, as seen in FIG. 4C. Force "F" may be created in any suitable
manner, including but not limited to the employ of a clamp,
crimping, or coining apparatus (not shown).
[0039] Alternatively, rather than directing the beams 302 at the
internal region 212 of surgical fiber 200, the beams 302 may be
directed to remove material from the outer surface 214 thereof, as
seen in FIG. 4D. To regulate the amount of material removed from
outer surface 214, the beams 302 may be directed progressively
inward, i.e. towards axis "A", during the irradiation period.
Moreover, by varying the irradiation period and/or one or more
parameters of the irradiating device 300 or beams 302, e.g. the
scan rate, peak power, pulse repetition rate, spot size, energy per
pulse, pulse width, or wavelength, the amount of material removed
from surgical fiber 200 may be further controlled, thereby
permitting the formation of a reduced portion 204 (FIG. 4E)
defining a particular or desired outer dimension "D.sub.2" and/or
axial dimension "L".
[0040] With reference now to FIGS. 5A-5B, in still another aspect
of the present disclosure, a method of altering surgical fiber 200,
e.g. reducing the initial outer dimension "D.sub.1" thereof, is
disclosed which employs a plurality of irradiating devices 300. Any
suitable number of irradiating devices 300 facilitating the even
irradiation of the surgical fiber 200 may be utilized. The
irradiating devices 300 are oriented about holder 304 and may be
spaced apart from one another along the axis "A" defined by the
surgical fiber 200.
[0041] In one embodiment, the holder 304 may be configured to
rotate the surgical fiber 200 about the axis "A" in the direction
indicated by arrows 1 and 2. Additionally, or alternatively, the
holder 304 may be adapted to translate along the longitudinal axis
"A" in the direction indicated arrows 3 and 4 to thereby
selectively define the axial dimension "L" of the reduced portion
204, as discussed above with respect to the embodiment of FIGS.
3A-3B. In an alternate embodiment, the irradiating devices 300 may
be configured to effect relative movement with respect to the
holder 304, e.g., the irradiating devices 300 may be configured to
revolve about the holder 304 in the directions indicated by arrows
5 and 6. In this embodiment, the plurality of irradiating devices
300 may also be configured to translate along the axis "A" in the
direction indicated by arrows 2 and 3.
[0042] Although the illustrative embodiments of the present
disclosure have been described herein with reference to the
accompanying drawings, the above description, disclosure, and
figures should not be construed as limiting, but merely as
exemplifications of particular embodiments. It is to be understood,
therefore, that the disclosure is not limited to those precise
embodiments, and that various other changes and modifications may
be effected therein by one skilled in the art without departing
from the scope or spirit of the disclosure.
* * * * *