Active Anvil Suture Looping With Ultrasonic Tapered Trimming
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Solution Overview
Problem
Current methods for forming looped sutures are inefficient and require manual intervention, lacking a systematic approach to create a tapered cut, which is essential for secure tissue attachment.
Innovation Solution
An automated system comprising a suture supply assembly, gripping assemblies, a welding assembly with an active anvil, and a trimming assembly that uses ultrasonic energy to form a looped suture with a tapered cut, ensuring secure tissue integration.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual methods are used to form looped sutures, then flexibility in handling is maintained, but productivity is low and manual errors increase
Solution Approach 1:
The automated suture forming system performs loop creation, welding, and trimming operations automatically without requiring manual intervention in the operating room. The system self-manages the entire suture preparation process from feed to finished looped suture, eliminating manual errors while maintaining surgical flexibility.
Solution Approach 2:
Manual mechanical operations are replaced with an automated mechanical system that uses controlled feeding, ultrasonic welding, and precision trimming mechanisms. This substitution increases productivity and consistency while reducing human error in suture formation.
2Reliability
If a loop is formed in the suture during manufacture, then tissue attachment is improved, but the suture requires additional processing steps
Solution Approach 1:
The patent combines loop formation, welding, and trimming operations into a single integrated automated system. This merging of operations creates the looped suture with tapered ends in one continuous process, improving tissue attachment security while eliminating multiple separate processing steps.
Solution Approach 2:
The system performs all necessary suture processing operations including loop formation and welding before the suture leaves the manufacturing facility. This preliminary action ensures the suture is fully prepared with secure tissue attachment capabilities before reaching the surgical environment.
3Ease of operation
If a tapered cut is added to the looped suture, then insertion into tissue is facilitated, but manufacturing precision requirements increase
Solution Approach 1:
The tapered cut is created using ultrasonic welding technology, which replaces traditional mechanical cutting methods. This substitution enables precise control of the taper angle and depth through ultrasonic vibration parameters, achieving the required manufacturing precision while facilitating easy suture insertion into tissue.
Solution Approach 2:
The system controls the taper geometry by adjusting ultrasonic welding parameters such as amplitude, frequency, and duration. These parameter changes allow precise control over the tapered cut characteristics, achieving the optimal balance between insertion ease and manufacturing precision.
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 efficient and secure formation of looped sutures with tapered ends, facilitating easier insertion and stronger tissue attachment, reducing manual errors and improving surgical efficiency.
Implementation Method 1
a welding assembly with an active anvil, the active anvil assembly comprising an anvil member and a first sensor incorporated within the anvil base and configured to interact with and provide force feedback to the active anvil assembly during the joining and trimming processes
Implementation Method 2
a trimming assembly configured to cut a tapered surface into the looped end portion of the suture
Data Source
Figure 1A~1C
Figure 2
Figure 3
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.