Method of manufacturing a surgical instrument or prosthesis

• US 9,770,855 B2
• Filed: 05/11/2012
• Issued: 09/26/2017
• Est. Priority Date: 05/12/2011
• Status: Active Grant

• Current Assignee: Depuy Ireland Unlimited Company (Johnson & Johnson), Viant AS&O Holdings, LLC (Viant Medical, LLC)
• Original Assignee: Lake Region Medical, Inc. (Integer Holdings Corporation Inc), Depuy Ireland Unlimited Company (Johnson & Johnson)
• Inventors: Asselin, Henri, Reeve, Michael, Beaupre, Todd
• Primary Examiner(s): Lee, Edmund
• Application Number:
  US14/117,121
• Publication Number:
  US 20150174801A1
• Time in Patent Office: 1,964 Days
• Field of Search: None
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2090/3937 Visible markers
• CPC Class Codes: A61F 2240/001 Designing or manufacturing processes
• CPC Class Codes: B29C 2045/167 injecting the second layer through the first layer
• CPC Class Codes: B29C 45/0003 of successively moulded portions rigidly joined to each other
• CPC Class Codes: B29C 45/16 Making multilayered or multicoloured articles B29C45/0062 takes precedence; feeding colouring materials into the injection unit B29C45/1816
• CPC Class Codes: B29L 2031/7532 Artificial members, protheses
• CPC Class Codes: B29L 2031/7546 Surgical equipment
• CPC Class Codes: Y10T 428/24802 Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]

Abstract

A method of manufacturing a surgical instrument or prosthesis and an injection moulded surgical instrument or prosthesis are described. A first material is injected into a first mould to form an interim component. A second material is injected into a second mould containing at least part of the interim component to form the surgical instrument or prosthesis such that portions of the first and second materials are exposed at the external surface of the surgical instrument or prosthesis. The first and second materials are visually distinct such that at least one exposed portion of the first or second material adjacent to an exposed portion of the other material forms a marking which is visible to a user.

Claims

1. A method of manufacturing a surgical instrument or prosthesis, comprising the steps of:

injecting a first material into a first mold to form an interim component; and

injecting a second material into a second mold containing at least part of the interim component to form the surgical instrument or prosthesis such that portions of the first and second materials are exposed at the external surface of the surgical instrument or prosthesis;

wherein the first and second materials are visually distinct such that at least one exposed portion of the first or second material adjacent to an exposed portion of the other material forms a marking which is visible to a user,

wherein in the step of injecting the second material into the second mold comprises injecting the second material such that the second material is deposited upon a selected portion of the surface of the interim component such that the second material in contact with the selected portion forms a marking;

wherein the selected portion of the surface of the interim component has a recess arranged to receive the second material to form the marking;

wherein the recess communicates with at least one blind hole formed in the interim component, the at least one blind hole spaced apart from the surface of the interim component surrounding the recess; and

wherein the blind hole is arranged to receive gas within the recess during the step of injecting the second material into the second mold.

2. The method of claim 1, wherein in the step of injecting the second material into the second mold comprises injecting the second material such that it partially or fully surrounds at least one portion of the interim component such that the first material in that portion forms a marking.

3. The method of claim 1, wherein the interim component has at least one aperture extending through a portion of the interim component, and wherein step of injecting the second material into the second mold comprises injecting the second material such that the second material flows through the aperture to the selected portion of the surface of the interim component.

4. The method of claim 3, wherein the interim component has at least one channel configured to direct the flow of the second material during the step of injecting the second material, the at least one channel communicating with the at least one aperture.

5. The method of claim 1, wherein the selected portion of the surface of the interim component is on an exterior surface of the interim component.

6. The method of claim 1, wherein the second mold is arranged to seal to the interim component surrounding the selected portion of the surface of the interim component to define the edge of the marking.

7. The method of claim 1, wherein the first and second materials are different colors.

8. The method of claim 1, wherein the marking is arranged to be recessed, flush or proud of the surrounding external surface of the surgical instrument or prosthesis.

9. The method of claim 1, wherein the first and second materials comprise a plastic material.

10. The method of claim 9, wherein the first and second plastics comprise the same plastic.

11. The method of claim 10, wherein at least one of the first and second plastics further comprise at least one additive.