Process of changing cross sectional shape within a textile
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Solution Overview
Problem
Current textile manufacturing machines are expensive and have slow production rates, and orthopedic sutures with flat cross-sectional shapes are preferred for stress distribution, but they require round or elliptical ends for ease of use with existing suture passer technology.
Innovation Solution
A method and apparatus for changing the cross-sectional shape of textiles, such as braided sutures, using a textile shaper with a heater and die to transform flat sections into non-flat shapes, including round or folded shapes, allowing for the creation of sutures with multiple cross-sectional sizes and shapes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If complicated machines are used to form textiles into final shape, then manufacturing precision is improved, but device complexity increases and productivity decreases
Solution Approach 1:
The patent applies parameter changes by utilizing temperature as a control parameter to alter the physical state of the textile material. The heating element raises the material temperature to a pliable state, enabling shape transformation without complex forming machinery. This thermal parameter change simplifies the device while achieving precise shape control through temperature-dependent material behavior.
Solution Approach 2:
The patent replaces complex mechanical shaping systems with a thermal field-based approach. Instead of using complicated mechanical devices to force the textile into shape, the invention uses heating to enable the material to naturally conform to the desired shape, substituting mechanical complexity with thermal processing simplicity.
2Manufacturing precision
If complicated machines are used to form textiles into final shape, then manufacturing precision is improved, but productivity worsens
Solution Approach 1:
The patent replaces slow, complex mechanical forming processes with rapid thermal processing. The heating element quickly brings the material to the required temperature state, enabling fast shape transformation and improving production rate while maintaining precision through controlled thermal fields rather than slow mechanical manipulation.
Solution Approach 2:
By changing the temperature parameter rapidly and controllably, the patent enables quick transitions between different material states, allowing for high-speed shape formation without sacrificing precision. The thermal parameter change occurs much faster than mechanical forming, thereby increasing productivity.
3Stress or pressure
If flat cross-sectional shape is used for suture, then stress distribution is improved, but ease of operation worsens due to incompatibility with suture passer technology
Solution Approach 1:
The patent applies local quality by creating different cross-sectional shapes at different locations along the suture. The body portion maintains a flat cross-section for optimal stress distribution, while the end portions are transformed into round cross-sections for compatibility with suture passer technology. This spatial variation in geometric quality allows both requirements to be satisfied simultaneously.
Solution Approach 2:
The patent segments the suture into distinct functional zones: a flat cross-sectional body portion for stress distribution and round cross-sectional end portions for instrumentation compatibility. This segmentation allows each segment to have optimized properties for its specific function, resolving the contradiction between stress distribution and ease of operation.
4Ease of manufacture
If uniform cross-sectional shape is used for entire suture, then manufacturing simplicity is improved, but adaptability worsens for different applications
Solution Approach 1:
The patent implements local quality by allowing different cross-sectional shapes at different locations along the suture length. The manufacturing process remains relatively simple using heating and die mechanisms, while the ability to create varied shapes (flat body, round ends) provides adaptability for different surgical applications and instrumentation requirements.
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
Enables efficient production of sutures with varying cross-sectional shapes, improving stress distribution and compatibility with existing instrumentation, while reducing production costs and time.
Implementation Method 1
The textile shaper can have a heater. When the segment third portion is in the heater, the segment third portion can be heatable from the first temperature to the second temperature.
Implementation Method 2
The textile shaper can have a die. When the textile is in the die, the textile can have the textile second cross-sectional shape.
Data Source
AI summary
Methods, systems, and devices for changing cross-sectional sizes and/or shapes of flat braided sutures and the resulting constructs are disclosed. The flat braided sutures can have a textile first cross-sectional shape that can be changed to a textile second cross-sectional shape. The systems can have a heater and a die. The flat braided sutures can be movable through the heater and the die. When the flat braided sutures are in the heater, the flat braided sutures can be heatable from a textile first temperature to a textile second temperature greater than the textile first temperature. When the flat braided sutures are at the textile second temperature, the textile first cross-sectional shape can be changeable to the textile second cross-sectional shape.