Braiding Machine With Moveable Arches For Tissue Regeneration Matrices
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Solution Overview
Problem
Existing braiding machines are unable to produce three-dimensional braided matrices with a suitable pore structure for even and random cell distribution and tissue growth, and they struggle to produce a variety of cross-sectional shapes and sizes continuously.
Innovation Solution
A braiding machine with moveable and stationary carrier holder arches that equalize yarn tension, allowing for uniform spacing and customizable braided structures, including splits, to create three-dimensional matrices suitable for tissue regeneration and surgical meshes.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Speed
If standard maypole braiding machines are used, then braiding can be performed, but the maximum speed of rotation is severely limited by inertia forces and vibration caused by changing the path of carriers
Solution Approach 1:
The patent employs a rotary braiding mechanism where carriers move in a continuous circular path rather than changing direction repeatedly. This dynamic continuous motion eliminates the inertia forces and vibration associated with directional changes, enabling higher operating speeds while maintaining braiding quality.
Solution Approach 2:
The invention replaces the traditional maypole mechanical carrier system with a rotary mechanism that uses a different mechanical approach - instead of carriers changing direction, the entire carrier assembly rotates continuously, substituting the mechanical path-change system with a rotational system that avoids harmful inertia effects.
2Length of moving object
If bobbins are made small to reduce strand length limits, then carrier path length is reduced, but the length of strands on each carrier is severely limited making it necessary to frequently stop to replenish
Solution Approach 1:
The rotary braiding mechanism enables continuous operation without interruption. The continuous circular motion of carriers allows uninterrupted yarn feeding and braid formation, eliminating the need to stop for replenishment and maintaining continuous productive action throughout the braiding process.
Solution Approach 2:
The system is designed to accommodate sufficient strand length from the beginning, allowing the braiding process to proceed continuously without needing to replenish during operation. The preliminary configuration of the rotary mechanism ensures that adequate yarn supply is maintained throughout the continuous braiding process.
3Shape
If rotary braiding machines with strand deflectors are used, then carriers can follow circular paths, but the forces on deflectors are quite high and many strand materials cannot be braided
Solution Approach 1:
The patent removes the strand deflectors from the system entirely. Instead of using deflectors to redirect strands, the invention allows carriers to follow their circular paths directly without intermediate deflection components, eliminating the high forces that prevented braiding of many strand materials.
Solution Approach 2:
Rather than using deflectors to change strand direction, the invention inverts the approach by having the carriers themselves follow the circular path and directly deliver strands to the braid point, eliminating the need for separate deflection mechanisms and reducing forces on the strand path.
4Ease of operation
If lever arm machines are used, then strands can be entrained across paths, but obtaining a symmetrical braid has been difficult
Solution Approach 1:
The rotary carrier system performs multiple functions simultaneously - the carriers both follow their circular paths and directly deliver strands to the braid point without requiring separate entrainment mechanisms. This multi-functionality simplifies the system and improves braid symmetry by eliminating the complexity of lever arm mechanisms.
Data Source
AI summary
A braiding machine for that produces three-dimensional braided matrices with a suitable pore structure for even and random distribution and in-growth of cells for tissue growth and repair is described herein. Methods for making three-dimensional matrices with controlled thicknesses and porosity and the resulting matrices are also described. The machine contains curved arches that hold the plurality of carriers. At least two of the arches are moveable in a side-to-side direction. Additionally, a controlled pushing mechanism pushes the carriers up and down the slots in the arches. These motions allow one to form three-dimensional braided matrices that provide sufficient porosity and mechanical support for tissue growth and repair in a variety of sites in the body.