TECHNICAL FIELD

The invention relates to a machine that enables the threads called sutures used in surgeries to be cut and processed to make them ready for use.

In particular, the invention relates to the machine that enables multiple cutting of surgical multifilament threads and hardening of the ends for connection to the needle after cutting.

BACKGROUND

In surgeries, tissue incisions are attached to each other using special threads, and healing is ensured in this way. Alternative types of threads and needles are used based on the type and region of the surgery, and these threads are presented sterile for the use of the surgeon.

During the surgery or suture procedures of the incisions, the procedure is performed by holding the suture needles with the suture holder, and the suture needle ready to be packaged during the surgery or operation is removed by directly holding with the suture holder and the procedure is continued. It is important that this operation is fast and comfortable, especially when the surgical condition is considered. For this reason, suture threads are cut in the prescribed sizes and presented as connected to suture needles.

Surgical threads are generally made of synthetic material and are produced as monofilament or multifilament. Due to their structure, multifilament threads have frayed ends. Particularly in the case of cutting, the end parts are scattered, which prevents the suture needle from entering the end part. The entire end of the thread must be inside the needle in order to avoid any problems, especially during the operation.

In order to solve the said problem, the surgical threads are cut into the desired sizes in the art, the ends are hardened and then fixed by placing them in the suture needle. In known applications, multiple or linear single cutting techniques can be applied, and then the ends of the threads can be hardened by alternative methods. One of them is the hardening process carried out by using biocompatible adhesive and the other is the hardening process carried out by applying heat. In heat applied methods, direct heat is applied to the end of the thread from the heat source and the end of the thread is hardened.

In heat applications, the end of the threads are kept between the heating plates, and the threads are taken from this section after the optimum time. The heat transfer method used in this method is heat transfer. Although more stable results are obtained compared to adhesion, it causes low- capacity production in mass production, especially in multiple hardening processes. Multiple surgical thread coils are required to be used in the same main for capacity increase. Since the coil life of absorbable threads is limited, operating more than one coil at the same time can cause problems in low quantity productions and cause an increase in the waste rate. Since the heater plates operate continuously, they also heat the environment. Since surgical thread production is carried out under clean room conditions, factors that increase the ambient temperature are a negative factor for the production site. For this reason, the adhesive application is more commonly used in high capacity demands.

USPTO patent document with publication number US20050125037A1 refers to embodiments in which the suture thread is shaped by heat plates. In this embodiment, there are the said multiple production problems.

In the USPTO patent document with publication number US5643628A discloses the method of suture thread production, which is automatically applied with adhesive.

All the problems mentioned above have made it necessary to make an innovation in the relevant field as a result.

THE OBJECTS OF THE INVENTION

The present invention is put forward to eliminate the aforementioned problems and to make a technical innovation in the relevant field.

The main object of the invention is to reveal the machine structure that enables the threads to be cut and the ends to be hardened in order to ensure that a large number of suture threads are prepared automatically in the unit time.

Another object of the invention is to prevent the increase of ambient temperature by operating the heat source only during the hardening process.

Another object of the invention is to ensure that the heat is collected only in the area to be hardened with special reflectors of the heat source.

Another object of the invention is to prevent the dispersion of infrared rays with the reflectors of the heat source.

Another object of the invention is to ensure that the wastes in production are kept to a minimum by cutting the thread at the specified angle.

Another object of the invention is to allow high capacity mass production with the machine located in a small area.

Another object of the invention is to allow production to a certain standard by ensuring that the hardened parts of all cut and hardened threads are equal.

Another object of the invention is to prevent the deterioration/loss of quality of the threads by heating the environment during the hardening process.

BRIEF DESCRIPTION OF THE INVENTION

The present invention is a surgical thread cutting and hardening machine in order to realize all the objects that will emerge from the abovementioned and the following detailed description.

The invention relates to the machine, which provides hardening and cutting of surgical threads and prepares the thread end to be placed on the suture needle to prevent fraying, characterized in that it comprises a heater/cutter mechanism containing the cutter mechanism and the heating unit, which is rotatable and linearly movable on its axis, a winding mechanism which is aligned with the said heater/cutter mechanism on at least one axis, at least one drum which enables the thread to be wound thereon by rotating on at least one axis on the said winding mechanism, a lower reflector which consists of at least one part on the said drum, at least one upper reflector on the heating unit which provides heating of the threads wound on the drum, at least one heater which remains inside when the said upper reflector is joined with the lower reflector, and at least one cutter mechanism on the cutter mechanism to enable the threads wound on the drum to be cut.

The invention is a method of preventing fraying by hardening the ends of the threads to be cut at the desired dimensions by wrapping the surgical threads on at least one cylindrical form, characterized in that the said thread is kept between the lower reflector and the upper reflector by covering the threads wound on the drum comprising at least one lower reflector structure at can be aligned exactly with the upper reflector of the heating unit by rotating the drum on its axis, in that regional heating process is carried out in the threads by irradiation in the closed area created by and the upper reflector and the lower reflector with at least one infrared heater in the said upper reflector.

Another preferred embodiment of the invention comprises at least two winding members connected to the side plate on both sides, forming the outer edges to enable the threads to be wound on the drum rotatable on its axis.

Another preferred embodiment of the invention comprises a drum having at least one lower reflector positioned inwards from the outer edge of the said successive winding members between two successive winding members.

Another preferred embodiment of the invention comprises more than two winding members fixed between two side plates in such a way that the linear length in a turn around the axis of the period is the desired length of the thread when the thread is wound on the drum in accordance with the length of the thread to be cut.

Another preferred embodiment of the invention comprises a thread transfer mechanism with a tension setting mechanism that allows the tension of the thread to be wound on it by rotating the drum with mechanical force on its axis.

Another preferred embodiment of the invention comprises a thread transfer slide positioned parallel to the drum and a thread transfer carriage that can be moved linearly on the thread transfer slide in order to ensure that the pulley with the thread to be wound on the drum is aligned with the drum and the thread on the drum is oriented not to overlap.

Another preferred embodiment of the invention comprises a drum fixed to the side plate comprising a lower reflector fixing opening positioned in the same direction with each other to enable the lower reflector to be fixed.

Another preferred embodiment of the invention comprises a drum axis member located at the center of at least one of the side plates to allow the drum to rotate on a single axis.

Another preferred embodiment of the invention comprises at least two lower reflector bodies to ensure that the lower reflector is fixed on the side plate.

Another preferred embodiment of the invention comprises at least one lower reflector retaining bracket to ensure that the lower reflector is fixed on the lower reflector body.

Another preferred embodiment of the invention comprises at least two drum brackets that allow the drum to be fixed on the machine body and to be bedded over the drum axis members.

Another preferred embodiment of the invention comprises a cutter that enables the threads to be cut with the knife that moves linearly on at least one slide so as to move parallel to the drum positioned between the heater/cutter side bodies in order to ensure the cutting of the threads wound on the drum along the drum.

Another preferred embodiment of the invention comprises a circular knife rotated by at least one electric motor on its axis to be in contact at an angle of 45° with the threads.

Another preferred embodiment of the invention comprises a heater which is an IR heater.

Another preferred embodiment of the invention comprises at least one heater bracket that enables the heater to be fixed in the upper reflector.

Another preferred embodiment of the invention comprises an upper reflector with an outer radius to provide a homogeneous reflection of the IR rays. Another preferred embodiment of the invention has a lower reflector comprising an inner radius, which allows the threads to be rigidly hardened by reversing the rays reflected from the upper reflector or forming a distance to prevent the contact of the cutter with the lower reflector during cutting.

Another preferred embodiment of the invention comprises a lower reflector and upper reflector that are made of metal material and allow the IR light to be reflected.

Another preferred embodiment of the invention comprises two side panels positioned at the edges of the upper reflector to hold the heater completely inside and prevent the reflectance of IR light outside when it joins the lower reflector.

Another preferred embodiment of the invention has which has the structure of the heating unit and the cutter mechanism positioned in different positions on the heater/cutter mechanism in order to determine the working position by rotating on the same axis, and which has the process of rotating the heater/cutter mechanism on its axis and approximating the heater/cutter mechanism to the drum with a linear movement to ensure the approximation of the relevant unit to the drum according to the operation to be performed on the thread wound on the drum.

The scope of protection of the invention is specified in the claims and cannot be limited to those explained for sampling purposes in this brief and detailed description. It is evident that a person skilled in the art may exhibit similar embodiments in light of the above-mentioned facts without drifting apart from the main theme of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 shows a front view of the machine.

Figure 2 shows a perspective view of the cutting machine.

Figure 3 shows a perspective view of the drum with the brackets.

Figure 4 shows a perspective view of the drum. Figure 5 shows a perspective cold of the drum and the lower reflector part on the drum.

Figure 6 shows a perspective view showing the positioning of the upper reflector and the lower reflector with the source.

Figure 7 shows a cross-sectional view of the reflector and source.

Figure 8 shows a perspective view of the reflector and source.

Figure 9 shows a perspective view of the mechanism that enables the transfer of the thread of the invention.

Figure 10 shows the drawing showing the cutting angle of the cutter.

Figures 11 A, B, C, D, E, F, G, I, J shows alternative embodiments of the reflector section.

DESCRIPTION OF THE REFERENCE NUMBERS IN THE FIGURES

10. Machine body

11. Controller

20. Winding mechanism

21. Drum

210. Side plate

2101. Lower reflector fixing opening

2102. Centering flange

2103. Drum axis member

211. Winding member

2110. Winding member fixing bolt

22. Drum bracket

30. Heater/cutter mechanism

300. Heater/cutter mechanism side body

31. Cutter

311. Knife 40. Thread transfer mechanism

41. Thread transfer slide

42. Thread transfer carriage

43. Pulley

44. Tension setting mechanism

50. Heating unit

51. Lower reflector

510. Lower reflector body

511. Inner radius

512. Lower reflector retaining bracket

52. Upper reflector

521. Outer radius

53. Heater

531. Heater bracket

M. Machine

DETAILED DESCRIPTION OF THE INVENTION

In this detailed description, the cutting and hardening machine for surgical threads of the invention is explained only with examples that will not have any limiting effect in order to better understand the subject matter.

The invention relates to a machine (M) that enables multiple cutting of surgical multifilament threads and hardening of the ends to connect them to the needle after cutting.

The invention is characterized in that it comprises a heater/cutter mechanism (30) containing the cutter mechanism (310) and the heating unit (50), which is rotatable and linearly movable on its axis, a winding mechanism (20) which is aligned with the said heater/cutter mechanism (30) on at least one axis, at least one drum (21) which enables the thread to be wound thereon by rotating on at least one axis on the said winding mechanism (20), a lower reflector (51) which consists of at least one part on the said drum (21), at least one upper reflector (52) on the heating unit (50) which provides heating of the threads wound on the drum (21), at least one heater (53) which remains inside when the said upper reflector (52) is joined with the lower reflector (51), and at least one cutter (31) on the cutter mechanism (310) to enable the threads wound on the drum (21) to be cut. Figures 11 A, B, C, D, E, F, G, I, J show alternative embodiments of the said reflector section.

Figure 1 shows a front view of the invention. The machine body (10) includes a wrapping mechanism (20) and a heater/cutter mechanism (30), which are at least two independently movable parts. The cutter (31), which has a knife (311) that allows the threads to be cut by intervening on the wrapping mechanism (20), has at least one thread transfer mechanism (40) to enable the threads to be wrapped on the wrapping mechanism (20). The thread transfer mechanism (40) allows the thread to be wrapped rigidly at the specified tension when winding on the drum (21) that the thread wrapping mechanism (20) has.

The heater/cutter mechanism (30) of the invention preferably houses the cutter mechanism (310) and the heating unit (50) positioned 180° with each other. The correct control and supervision of the moving mechanisms are carried out by the controller (11).

Figure 2 shows a perspective view of the heater/cutter mechanism (30) of the invention. In the said embodiment, the heating unit (50) and the cutter mechanism (310) are gathered in the same unit together with the heater/cutter mechanism side body (300), and it is practically ensured that the selected unit is activated according to the preferred process moment. The working units are preferably the units remaining at the lower part and are working on the winding mechanism (20). In alternative embodiments of the invention, these positions may vary or the wrapping mechanism (20) may be positioned on the lower and upper parts of the machine (M). By rotating the heater/cutter mechanism (30) of the invention in its axis, the position of the cutter mechanism (31) or the heating unit (50) can be controlled. In the preferred embodiment of the invention, the heater/cutter mechanism (30) can be rotated by at least one electric motor from the axis of the heater/cutter mechanism side body (300). The correct position can be monitored instantly by the controller (11) with the position sensors used. The heater/cutter mechanism (30) can rotate on its axis and move linearly on the vertical axis.

Figure 10 shows the side view of the cutter (31) of the invention. The cutter (31) can move linearly in the slides on the heater/cutter mechanism (30). The said movement is preferably controlled by at least one servo motor and can also be controlled manually in alternative embodiments. The linear movement preferably takes place perpendicular to the thread direction wound on the drum (21). In the preferred embodiment, at the point where the knife (311) of the cutter (31) contacts the thread, there is a 45° angle between the thread and the knife (311). In this way, the thread is cut in the most effective way. The said angle can be seen in Figure 10.

Figures 6, 7, and 8 show detailed drawings of the heating unit (50) located on the heater/cutter mechanism (30). The said heating unit (50) is positioned with the upper reflector (52) at the top and the lower reflector (51) at the bottom during the application. The heater (53) is positioned between the lower reflector (51) and the upper reflector (52) and is connected to the upper reflector (52). The connection is preferably made by the heater bracket (531). The movement of the upper reflector (52) and the heater (53) is controlled by the heater/cutter mechanism (30). The control of the movement of the upper reflector (52) and the members connected to the upper reflector (52) is controlled by the movement of the heater/cutter mechanism (30).

The lower reflector (51) of the heating unit (50) is preferably fixed on the drum (21) and is movable only by the movement of the drum (21).

Figure 3 shows the perspective cold of the winding mechanism (20) of the invention. The said wrapping mechanism (20) includes a drum (21) that allows the thread to be wrapped and processed. The said drum (21) is connected to the machine body (10) by at least two drum brackets (22). By rotating the drum (21) on its axis, the thread is wound on it. Furthermore, cutting and hardening of the thread by the units on the heater/cutter mechanism (30) takes place on the drum (21).

The said drum (21) comprises at least three winding members (211) positioned between at least two side plates (210). The winding members (211) are fixed on the side plates (210) by the winding member fixing bolts (2110) and the thread is wound on the winding members (211) by rotating the drum (21) in the axis of the side plates (210). The said drum (21) is supported to the drum bracket (22) by at least one drum axis member (2103) located in the center of the side plates (210). A detailed drawing of the drum (21) is given in Figure 5. The drum axis members (2103) are adapted to the center of the side plate (210) by the mating flanges (2102). The rotation of the drum (21) is preferably carried out by at least one electric motor.

In the preferred embodiment of the invention, the winding members (211) fixed between the two side plates (210) to form the drum (21) are shafts with cylindrical surface form. There is at least one lower reflector fixing opening (2101) on the two side plates (210) forming the drum (21). The lower reflector fixing opening (2101) is positioned between two successive winding members (211), on which the lower reflector (51) is fixed. By means of the said opening, the lower reflector (51) is provided to be lower than the peak of the two winding members (211) following the lower reflector (51) away from the center. In this way, during the winding of the thread to the winding members (211) on the drum (21), the lower reflector (51) is located at the bottom of the winding threads, in the inner part of the drum (21).

As shown in Figure 5, there are alternative embodiments that enable the said lower reflector (51) to be fixed on the drum (21). In the preferred embodiment, the lower reflector (51) can be fixed by the lower reflector retaining brackets (512) located on the lower reflector body (510). Preferably, the lower reflector body (510) enables the lower reflector (51) to be connected to the drum (21).

In the preferred embodiment of the invention, there is at least one radius (51) on the lower reflector (51). It provides an optimum reflection of the rays by the inner radius (51).

Figure 7 shows a cross-sectional view of the heating unit (50). When the upper reflector (52) on the heater/cutter mechanism (30) is positioned on the drum (21), it is positioned on the lower reflector (51). The heater (53) is located inside the upper reflector (52). In the preferred embodiment, the upper reflector (52) of the invention is positioned on the outer radius (521) at the upper part. In the preferred embodiment, the heater (53) is fixed to the upper reflector (52) by means of the heater bracket (531). The threads wound on the drum (21) and to be hardened are located between the upper reflector (52) and the lower reflector (51). The part of the threads that are wound on the threads by the rays transmitted by the heater (53) is provided to harden. It is ensured that the form of the upper reflector (52) and the internal radius (511) of the lower reflector (51) reflect the IR rays coming out of the heater (53) in the interior of the reflectors in an optimum way and that the hardening process is best performed.

Figure 8 shows the position of the reflectors during operation. When the upper reflector (52) and the lower reflector (51) are closed by means of the side panel on both sides connected or monolithic on the upper reflector (52), the leakage of IR light from the inside to the outside is prevented. In the preferred embodiment of the invention, the upper reflector (52) comprises an antireflection plate enabling the edges thereof to be closed. In this way, the leakage/passage of rays into the environment is prevented while the hardening process is carried out.

The heater (53) used in the preferred embodiment of the invention is preferably an IR heater.

Figure 9 shows a perspective view of the thread transfer mechanism (40). The thread transfer mechanism (40) controls the winding of the thread on the coil on the drum (21) in the desired order and tension. The thread transfer mechanism (40) is positioned parallel to the drum (21) and can move linearly in this direction. The thread transfer slide (41) is positioned parallel to the drum (21) and the thread transfer carriage (42) on the thread transfer slide (41) can move linearly. The said linear movement can be controlled by at least one stepping motor or servo motor. The tension of the thread taken from the pulley (43) is adjusted by the tension setting mechanism (44) on the thread transfer carriage (42). The winding process on the drum (21) is carried out by rotating the drum (21), and the thread transfer carriage (42) moves linearly in order not to overlap the wound threads.

After a sufficient amount of thread is wound on the drum (21), the rotation of the drum (21) stops. The drum (21) is positioned to remain in the top position of the lower reflector (51) unit on it. During the hardening process, it is ensured that the upper reflector (52) unit, which is housed by the heating unit (50) of the heater/cutter mechanism (30) that can rotate in its axis, is positioned on the lower reflector (51) on the drum (21). The said action is realized by the linear movement of the heater/cutter mechanism (30) in the direction of the drum. By energizing the heater (53) for the specified time, an IR ray is emitted on the threads wound on the drum (21) and the threads are hardened.

After the threads have hardened, the heater/cutter mechanism (30) rises linearly and moves linearly in the direction of the drum (21) by positioning the cutter mechanism (300) in the direction of the drum (21). The knife (311) of the cutter (31) is a circular release and is rotated by at least one electric motor. The process is completed by cutting the threads from the part where they harden.

The system of the invention operates completely automatically and movement is provided by electromechanical or pneumatic systems controlled by the controller (11). In the preferred embodiment of the invention, the movement of the heater/cutter mechanism (30) is controlled pneumatically. In the preferred embodiment of the invention, the lower reflector (51) and the upper reflector (52) are made of material that will reflect the IR rays. In an alternative embodiment, the interior may comprise a coating.

Within the scope of the invention, the synchronous operation can be carried out by using more than one drum (21) on the same machine, and the production capacity can be increased by extending the length of the machine (M). In addition, regional heating is performed in the hardening process with the IR heater and the heating of the environment is prevented.