Compound Barb Medical Device Ultrasonic Cutting

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Solution Overview

Problem

Existing methods for forming barbs on medical devices, such as sutures, are often difficult or costly to implement, and there is a need for a method that can produce barbs with varying orientations and configurations to suit different medical applications, including random, reduced, and bi-directional arrangements.

Innovation Solution

A compound barb medical device is created by forming barbs with multiple portions at different angles relative to the longitudinal axis of the device, using a method that involves applying vibrational energy to a cutting element to cut the device at specific ratios of cut depth to diameter, allowing for the formation of linear or non-linear barbs that can be oriented in various patterns.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If traditional methods are used to form barbs on sutures, then the manufacturing process is simple, but the implementation cost is high and the manufacturing precision is limited

Engineering Contradiction:

Improvebarb configuration precisionVSAvoidmanufacturing complexity

Core Design Contradiction:

Manufacturing precisionVSEase of manufacture

Solution Approach 1:

The patent applies ultrasonic vibration to a cutting element to form barbs on the suture. The vibrational energy enables precise cutting and shaping of barbs with controlled depth and orientation, achieving high manufacturing precision while maintaining ease of manufacture through a streamlined process.

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The patent controls barb formation by adjusting parameters such as ultrasonic power, cutting depth ratio (cut depth to diameter), and vibration frequency. These parameter changes enable precise control over barb configuration, orientation, and depth, resolving the contradiction between precision and manufacturing complexity.

Inventive Principle:

Principle #35Parameter changes

2Adaptability or versatility

If barbs are formed with multiple orientations and configurations, then the adaptability to different medical applications is improved, but the device complexity increases

Engineering Contradiction:

Improvebarb configuration versatilityVSAvoidbarb structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The patent creates barbs with segmented structures consisting of multiple portions (first portion, second portion, and optionally third portion) at different orientations. Each portion can be independently controlled, allowing versatile configurations for different medical applications while maintaining manageable device complexity through modular barb design.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The patent employs asymmetric barb configurations where different portions of the barb are oriented at different angles relative to the longitudinal axis (e.g., first angle for first portion, second angle for second portion). This asymmetry provides adaptability for various tissue types and surgical needs while the systematic approach to creating these asymmetric features keeps manufacturing complexity controlled.

Inventive Principle:

Principle #4Asymmetry

3Strength

If compound barbs with multiple portions at different angles are formed, then the tissue holding capability is enhanced, but the manufacturing precision requirements increase

Engineering Contradiction:

Improvetissue holding capabilityVSAvoidcut depth and orientation precision

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

Ultrasonic vibration of the cutting element enables precise control over cut depth and orientation while forming compound barbs with multiple portions. The vibrational energy allows the cutting element to achieve the required manufacturing precision for complex barb geometries without excessive force or heat, enhancing tissue holding capability through well-defined barb structures.

Inventive Principle:

Principle #18Mechanical vibration

Solution Approach 2:

The patent replaces traditional mechanical cutting methods with ultrasonic vibration-based cutting. This substitution enables higher precision in forming compound barbs with multiple oriented portions, as ultrasonic vibration provides finer control over material removal and reduces the risk of burr formation or uneven cuts that would compromise manufacturing precision.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

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

This approach enables the production of barbed sutures with customizable barb configurations, enhancing tissue holding capabilities while reducing implementation costs and complexity, suitable for diverse medical procedures.

Implementation Method 1

applying vibrational energy to a cutting element to form a compound barb on at least a portion of the medical device

Methodology Applied

Scientific EffectVibrational energy: Vibration

Data Source

PatentUS20230309990A1Compound barb medical device and method

Publication Date: 2023.10.05 COVIDIEN LP

AI summary

A compound barb medical device is provided which includes an elongated body having at least one barb formed along the length of the body, the barb defining an inner surface with a first portion disposed at a first orientation relative to a longitudinal axis of the elongated body, and a second portion disposed at a second orientation relative to the longitudinal axis. Optionally, the barb defines a third portion disposed at a third orientation relative to the longitudinal axis. A method for forming a compound barb on a medical device is also provided.