Barbed Suture Knitting Method for Customizable Barb Configuration
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Solution Overview
Problem
Existing methods for forming barbed sutures are costly, time-consuming, and difficult to implement, especially when varying the size, location, and configuration of barbs is required for specific surgical applications, and they often weaken the suture material and introduce human error in knot-tying during surgical procedures.
Innovation Solution
A method using a warp knitting machine with two guide bars to produce a barbed suture by knitting chain stitch yarns and monofilament weft yarns, cutting the knit to create barbs that are stitched to the elongate body, allowing for varying barb size, location, and frequency without weakening the suture material.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If conventional cutting methods are used to form barbs on sutures, then barbs can be created on the suture surface, but the core of the suture is weakened and the manufacturing process becomes costly and time-consuming
Solution Approach 1:
Instead of cutting barbs from the suture core (which weakens it), the invention inverts the approach by knitting barbs as integral protrusions from the suture surface during the knitting process itself. The barbs are formed by the knitting pattern creating raised structures that become part of the suture fabric, eliminating the need for post-manufacturing cutting operations.
Solution Approach 2:
The barbs are formed preliminarily during the knitting process rather than being added or cut afterward. The knitting machine creates the barb structures as the suture is being manufactured, integrating the barb formation into the base production process and eliminating subsequent cutting steps.
2Manufacturing precision
If sophisticated cutting machines are used to create varied barb configurations, then precise barb size and location control is achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The knitting machine serves multiple functions: it creates the base suture structure and forms the barb configurations simultaneously through programmed knitting patterns. By changing the knitting program, different barb sizes, shapes, and distributions can be achieved with the same equipment, eliminating the need for multiple specialized cutting machines.
Solution Approach 2:
The invention controls barb configuration by changing knitting parameters such as stitch patterns, yarn selection, and machine guide bar programming. These parameter changes allow precise control over barb characteristics without requiring complex mechanical cutting equipment, achieving precision through software-controlled manufacturing parameters.
3Productivity
If barbs are formed by cutting into the suture body, then barbed suture is created, but production time increases and costs rise
Solution Approach 1:
The invention merges the suture production and barb formation processes into a single integrated knitting operation. Both the base suture and the barb structures are created simultaneously in one continuous manufacturing step, eliminating the separate cutting operation that would otherwise be required and significantly reducing total production time.
Data Source
AI summary
The invention relates to a method for forming a barbed suture (10) comprising:a) producing a knit by knitting together i) a set of chain stitch yarns (1) producing chain stitches and ii) a set of monofilament weft yarns completing weft stitches with at least one of said chain stitches, thereby producing at least one weft stitched chain stitch (6),b) cutting the knit along the warp direction on both sides of said weft stitched chain stitch, so as to isolate said weft stitched chain stitch from the rest of the produced knit,the chain stitch yarn of said at least one weft stitched chain stitch forming the elongate body (9) of the barbed suture and the monofilament cuts (7) extending from said weft stitches of said one weft stitched chain stitch forming the barbs (8) of said barbed suture.