Active Anvil Assembly for Tapered Looped Suture Formation
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Solution Overview
Problem
Current methods for forming looped sutures are manual and lack an efficient system for creating a tapered cut, which is necessary for secure tissue attachment and processing.
Innovation Solution
An automated system comprising an active anvil assembly with a sensor and control system, integrated with an ultrasonic welding horn, allows for precise formation of a looped suture with a tapered cut, including a trimming assembly for excess thread removal and a method involving ultrasonic welding and sensor feedback for torque, force, or distance control.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual methods are used for forming looped sutures, then flexibility and adaptability are maintained, but productivity and manufacturing precision are reduced
Solution Approach 1:
The automated suture forming system is divided into distinct functional modules: an ultrasonic welding assembly for joining thread ends, an active anvil assembly with sensor for controlled deformation, and a trimming assembly for excess thread removal. Each module performs a specific operation in sequence, enabling automated loop formation while maintaining manageable system complexity through functional segmentation.
Solution Approach 2:
The patent replaces manual mechanical operations with automated systems: ultrasonic vibration replaces manual friction-based heating for welding, sensor-controlled actuation replaces manual force application for loop deformation, and automated trimming replaces manual cutting. This substitution dramatically increases productivity while the modular architecture keeps device complexity manageable.
2Manufacturing precision
If automated ultrasonic welding is used to form loops, then manufacturing precision and productivity are improved, but device complexity increases
Solution Approach 1:
The active anvil assembly incorporates a sensor that provides real-time feedback on the thread deformation state during loop formation. This feedback enables the control system to adjust actuation parameters dynamically, ensuring precise loop geometry and consistent welding quality. The feedback mechanism allows high manufacturing precision without requiring overly complex mechanical positioning systems.
Solution Approach 2:
The ultrasonic welding assembly serves multiple functions: it heats and joins the thread ends to form the loop base, and subsequently welds the loop closure. The active anvil assembly both deforms the thread into a loop shape and provides the reaction force for welding. This multi-functionality reduces the number of separate components needed, managing device complexity while achieving high precision.
3Reliability
If a tapered cut is added to the looped suture, then tissue attachment reliability is improved, but manufacturing complexity increases
Solution Approach 1:
The trimming assembly applies the cutting action at a specific location and angle to create a tapered end geometry on the suture loop. This localized modification provides enhanced tissue attachment characteristics at the critical insertion point without requiring complex changes to the overall suture structure or manufacturing process. The taper is created by controlled angular contact during the trimming operation.
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 system enables the efficient and precise formation of looped sutures with tapered ends, enhancing tissue attachment and processing by providing a reliable and automated method for loop formation and trimming.
Implementation Method 1
The anvil member may be configured to operate with an ultrasonic welding horn to join a first length of a thread and a second length of the thread to form a loop in the thread
Data Source
AI summary
An active anvil assembly for use in forming a looped suture is provided. The active anvil assembly includes an anvil member, a first sensor operably connected to the anvil member, and a control assembly. The first sensor is configured for measuring at least one of force, torque, and distance feedback. Also provided are systems and methods for forming a looped suture including an active anvil assembly.