Braided Suture Coat Diameter Consistency
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Solution Overview
Problem
Existing braided surgical sutures often lack consistency in diameter and strength, leading to inefficiencies in manufacturing and increased waste due to irregularities in the braiding process, particularly when using multifilament strands with standard twisting and weaving parameters.
Innovation Solution
The method involves braiding multifilament strands with enhanced twisting (at least 150 turns/meter) and specific weaving densities (8-24 plaits/cm) to create a coreless suture stock that can be cut into consistent surgical sutures with improved strength and pliability, using a combination of UHMWPE and nylon filaments.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If standard twisting and weaving parameters are used for braiding multifilament strands, then the manufacturing process is simple, but the diameter consistency and strength of the suture are poor
Solution Approach 1:
The patent applies parameter changes by specifying precise twisting parameters (at least 150 turns/meter) and weaving density parameters (8-24 plaits/cm) to achieve consistent diameter and enhanced strength. These optimized parameters transform the braiding process into a controlled manufacturing process that produces uniform suture stock with improved mechanical properties.
Solution Approach 2:
The patent employs preliminary action by pre-twisting the multifilament strands to at least 150 turns/meter before braiding. This preliminary twisting action ensures that the strands are properly prepared and stabilized, which subsequently enables the braiding process to produce consistent diameter and uniform structure throughout the suture stock.
2Productivity
If standard braiding parameters are used, then the manufacturing process is efficient, but waste increases due to irregularities in the braiding process
Solution Approach 1:
The patent reduces waste by optimizing braiding parameters to at least 150 turns/meter twisting and 8-24 plaits/cm weaving density. These parameter changes eliminate irregularities in the braiding process, ensuring uniform diameter and consistent structure that minimize defects and reduce material waste while maintaining manufacturing efficiency.
3Strength
If multifilament strands with standard twisting are used, then the material processing is straightforward, but the knot strength and pliability are insufficient
Solution Approach 1:
The patent enhances knot strength and pliability by changing the twisting parameter to at least 150 turns/meter. This parameter modification optimizes the structural integrity of the multifilament strands, enabling them to form strong knots while maintaining adequate pliability for surgical manipulation, all while remaining straightforward to process.
Data Source
AI summary
High-consistency nonabsorbable braided suture stock of specified size is prepared from twisted multifilament strands braided together with a tightness of weave of less than 60 picks/inch. The suture stock can be cut to provide sutures, which may be combined with needles to provide surgical sutures for wound closure.