Barbed Suture Affixing System with Segmented Barb Assembly
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Solution Overview
Problem
Existing methods for forming barbed sutures are difficult, costly, and compromise the integrity of the suture material, lacking the ability to efficiently vary the size, number, location, and depth of barbs, and often require forming barbs from the suture material itself.
Innovation Solution
A system and method involving a suture supply mechanism and a barb supply mechanism that approximate to engage barbs with a suture, using a barb assembly with a base, retaining, and barb portion, securely affixing barbs to a multifilament or monofilament suture, allowing for adjustable barb configuration without compromising the suture material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If barbs are formed using mechanical cutting, laser cutting, injection molding, stamping, or extrusion from the suture material itself, then barbed sutures can be created with non-slip attribute, but the integrity of the suture is compromised and the manufacturing process becomes difficult and costly
Solution Approach 1:
The barb is divided into separate components: a barb body and a retaining portion. The retaining portion is separately formed and then attached to the barb body, which is then affixed to the suture. This segmentation allows each component to be optimized independently and simplifies the manufacturing process.
Solution Approach 2:
The retaining portion is extracted as a separate element from the barb structure. This separate retaining portion is formed independently and then attached to the barb body, eliminating the need to compromise the suture material during barb formation.
Solution Approach 3:
The retaining portion acts as an intermediary element that connects the barb body to the suture. This intermediary component facilitates the attachment process without requiring direct modification of the suture material, thereby preserving suture integrity.
2Adaptability or versatility
If conventional methods are used to form barbs on sutures, then barbed sutures can be produced, but the ability to efficiently vary the size, number, location, and depth of barbs is limited
Solution Approach 1:
The system allows dynamic adjustment of barb parameters including size, number, location, and depth. The separate formation of the retaining portion and barb body enables flexible configuration to meet different surgical requirements while maintaining efficient manufacturing through standardized attachment processes.
3Ease of manufacture
If barbs are formed from the suture material itself, then the barb structure can be created, but the suture material integrity is compromised
Solution Approach 1:
The retaining portion is extracted as a separate element that attaches to the barb body and then to the suture. This separation allows the barb to be formed without compromising the suture material, as the suture simply receives the pre-formed barb assembly rather than having barbs cut or molded from it.
Solution Approach 2:
The retaining portion serves as an intermediary that connects the barb body to the suture without requiring modification of the suture material. This intermediary component preserves the integrity of the suture while enabling secure barb attachment.
Data Source
AI summary
A system and method for affixing barbs on a suture are provided. In one embodiment, the system includes a suture supply mechanism for selectively retaining a length of suture and a barb supply mechanism for operably engaging a barb supply assembly including at least one barb. At least one of the suture supply mechanism and the barb supply mechanism are configured to approximate towards the other of the barb supply mechanism and suture supply mechanism to engage the at least one barb of the barb supply assembly with the suture of the suture supply assembly. Also provided are a barb for use in forming a barbed suture and a suture including at least one barb.