Double-Faced Barbed Prosthetic Knit via Warp Knitting
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
The existing methods for producing prosthetic knits with outwardly protruding barbs on both faces are time-consuming and require additional manual steps, making them inefficient for industrial production and versatile use in surgery.
Innovation Solution
A warp knitting process using at least four guide bars on a machine, where specific threading patterns generate loops on both faces that are then melted to form barbs, allowing for quick and simple production of barbs on both faces without supplementary manual steps, using biocompatible yarns like polypropylene and polylactic acid.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If manual steps are used to add barbs to the face of a prosthetic fabric after knitting, then barbs can be added to both faces, but the production process becomes time-consuming and complex
Solution Approach 1:
The knitting machine is configured with specific guide bar threading patterns that pre-establish the loop structures on both faces during the knitting process itself, eliminating the need for subsequent manual barb addition. The guide bars are threaded to create loops on alternating rows, with bar Bp1 creating loops on odd rows and bar Bp2 creating loops on even rows, so both faces have barbs formed before the fabric leaves the machine.
Solution Approach 2:
The process combines the knitting operation and barb formation into a single integrated step. By using multiple guide bars (Be, Bp1, Bp2, Bt) with specific threading patterns, the machine simultaneously knits the fabric structure and creates the barb loops on both faces in one continuous operation, rather than separating these functions into distinct manual steps.
2Adaptability or versatility
If manual steps are used to add barbs to prosthetic fabric, then barbs can be added to both faces, but the manufacturing process becomes awkward and complex
Solution Approach 1:
The knitting machine's guide bars are configured to automatically create the barb loops on both faces during normal knitting operation. The system serves itself by using the existing knitting mechanism and yarn feed system to generate the barb structures without requiring external manual intervention or specialized additional equipment.
Solution Approach 2:
The guide bars in the knitting machine perform multiple functions: bar Be creates the chain knit structure, bars Bp1 and Bp2 simultaneously create barb loops on opposite faces, and bar Bt provides weft connection. This multi-functionality allows a single knitting machine setup to produce complex double-faced barbed fabric without requiring separate operations.
3Productivity
If traditional knitting methods are used, then simple fabric can be produced, but barbs cannot be formed on both faces without additional steps
Solution Approach 1:
The threading pattern creates asymmetric loop formation on opposite faces - bar Bp1 places loops on odd rows while bar Bp2 places loops on even rows. This asymmetric timing and positioning of loop creation on the two faces allows both to develop barbs through the same melting process, achieving symmetry in the final product through asymmetric process steps.
Solution Approach 2:
The invention changes the physical state parameter of the loop material by melting it to transform the soft knitting loops into rigid barbs. This parameter change (from solid flexible yarn to melted rigid structure) occurs after the asymmetric loop placement, converting the temporary knitting structure into permanent barb features on both faces.
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 process enables the rapid and efficient manufacturing of prosthetic knits with barbs on both faces, suitable for attaching to biological tissues or other textiles, enhancing surgical applications by providing a quick and reliable fixation method.
Implementation Method 1
forming barbs by melting the loops
Data Source
Figure 1~2
Figure 3~5
AI summary
The present invention relates to a knit with outwardly protruding barbs on each of its faces, said knit being obtained by: i) knitting yarns on at least four guide bars, one bar forming a chain leaving one needle free in two; two bars threaded with monofilament yarn generating loops protruding outwards from the faces of said knit; the fourth bar producing the connection between the yarns of the three other bars, ii) thermosetting the knit obtained at i), iii) forming the barbs by melting the loops. The invention also relates to a prosthesis comprising such a knit.