Chemically Etched Rounded Needle Edges Without Hardness Loss
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Solution Overview
Problem
Conventional methods for manufacturing needles, especially those for microscopic surgery like ophthalmic needles, face challenges in maintaining precision and uniformity due to mechanical sharpening processes that can degrade the material's hardness, leading to dull edges and increased complexity for non-linear edge formations.
Innovation Solution
A chemically etched needle with rounded edges formed using a variable permeability mask and etching process, which maintains the metal's hardness and allows for precise, non-linear edge configurations without mechanical machining, reducing trauma during insertion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If mechanical sharpening processes (grinding, honing) are used to create needle edges, then sharp edges can be formed, but the material's hardness degrades and edges become dull quickly
Solution Approach 1:
The patent replaces mechanical sharpening processes (grinding, honing) with a chemical etching process using ferric chloride solution. This chemical method forms sharp edges without the mechanical contact that generates heat and causes tempering or annealing, thereby preserving the metal's hardness and edge durability
Solution Approach 2:
The patent changes the physical-chemical state of the metal surface through chemical etching, transforming the edge formation mechanism from mechanical removal to chemical dissolution. This parameter change allows edge formation without thermal effects that would degrade material properties
2Shape
If mechanical processes are used to create serrated, curved, or wavy edges, then non-linear edge formations can be achieved, but the process becomes more involved and complex
Solution Approach 1:
The patent replaces complex mechanical machining operations with a single chemical etching process. The chemical etchant naturally follows the mask pattern to create complex geometries (serrated, curved, wavy edges) without requiring multiple mechanical steps, tool changes, or specialized equipment
Solution Approach 2:
The patent changes the approach to complex shape formation by using chemical dissolution rates and mask patterns rather than mechanical tool paths. This allows complex edge geometries to be achieved through chemical parameter control (etchant concentration, exposure time, mask design) rather than mechanical process complexity
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The chemically etched needles with rounded edges provide improved durability and reduced tissue trauma during insertion, maintaining the metal's hardness and enabling precise, complex edge formations without the need for re-hardening, thus enhancing the longevity and performance of surgical needles.
Implementation Method 1
a chemically etched needle includes a metal base having a first side and a second side. The chemically etched needle also includes a chemically etched blade at one end of the metal base
Data Source
AI summary
A chemically etched needle is provided herein. The chemically etched needle includes a metal base having a first side and a second side. The chemically etched needle also includes a chemically etched blade at one end of the metal base and formed at an intersection of a distal diverging surface and a proximal diverging surface, at least one of the diverging surfaces slopes inward towards the second side.