Multi-Layer Collagen Construct for Medical Sutures
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Solution Overview
Problem
Current methods for creating medical constructs using collagen fibers lack a structured approach to achieve optimal mechanical properties and tissue integration, such as tensile strength and flexural stiffness, while also ensuring effective cell ingrowth and biocompatibility.
Innovation Solution
A multi-layered construct comprising an array of collagen fibers braided in specific patterns, with varying densities and orientations, and optionally coated with polylactic acid, to achieve enhanced mechanical properties and promote cell integration, along with an automated braiding system for consistent production.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If collagen fibers are braided in a multi-layered structure with varying densities, then tensile strength and flexural stiffness are improved, but manufacturing complexity increases
Solution Approach 1:
The construct is divided into multiple layers (first layer, second layer, third layer) with each layer containing a specific array of collagen fibers. The first layer has a first array, the second layer has a second array, and the third layer has a third array, allowing independent optimization of each layer's mechanical properties while maintaining overall structural integrity and tensile strength.
Solution Approach 2:
Different regions of the construct have different fiber densities and arrangements. The first layer has a first density of collagen fibers, the second layer has a second density, and the third layer has a third density. This local variation in quality allows optimization of tensile strength and flexural stiffness in specific regions while managing manufacturing complexity through standardized layering approaches.
2Strength
If collagen fibers are braided in a multi-layered structure with varying densities, then flexural stiffness is improved, but manufacturing precision requirements increase
Solution Approach 1:
The construct is segmented into three distinct layers, each with controlled fiber arrays. The first layer contains a first array of collagen fibers, the second layer contains a second array, and the third layer contains a third array. This segmentation allows flexural stiffness to be optimized through layer-specific fiber arrangements while managing manufacturing precision through modular construction.
Solution Approach 2:
The construct utilizes a composite structure combining multiple collagen fiber layers with potentially different orientations and densities. The first layer, second layer, and third layer each contribute different mechanical properties, creating a composite material system that achieves enhanced flexural stiffness through the synergistic arrangement of its components.
3Productivity
If an automated braiding system is used, then productivity is improved, but device complexity increases
Solution Approach 1:
The patent employs an automated braiding system that replaces manual or semi-manual braiding processes. This automated system uses mechanical or computational control to braid collagen fibers into the multi-layered construct structure, significantly improving production efficiency and consistency while reducing human labor requirements and variability.
Solution Approach 2:
The automated braiding system allows for precise control and variation of braiding parameters such as fiber density, layer thickness, and braid pattern. By programmatically changing these parameters during manufacturing, the system can produce constructs with optimized mechanical properties while maintaining high productivity through automated process control.
Data Source
AI summary
The present disclosure describes a medical construct. The medical construct includes a first layer comprising an array of collagen fibers, the first layer forming a core of the medical construct, and a second layer comprising a plurality of braided collagen fibers, wherein the second layer surrounds the core of the medical construct. In some embodiments, the medical construct may further include a third layer comprising a plurality of braided collagen fibers, wherein the third layer surrounds the second layer. Methods of manufacturing a medical construct also provided.