Continuous Braided Closed Loop Implant Manufacturing
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Solution Overview
Problem
Current devices for securing soft tissue to bone, such as sutures and suture anchors, face challenges in efficiently creating continuous braided closed loops, which are time-consuming, prone to user error, and costly, especially when using multiple filaments, leading to potential failure and increased manufacturing complexity.
Innovation Solution
The development of surgical implants with continuous braided closed filament loops formed from a single or multiple strands of filament, where the loops are configured with a braided pattern using a mandrel with staggered posts, allowing for automated formation and attachment to implants like suture anchors or cortical buttons, reducing manual intervention and increasing efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If multiple separate filaments are used to form braided closed loops manually, then the loop can be formed with desired strength, but the process becomes time-consuming and prone to user error
Solution Approach 1:
The patent applies preliminary action by pre-configuring the braided loop structure during manufacturing before surgical use. The loop is formed with predetermined braiding patterns and filament arrangements, eliminating the need for manual weaving during surgery. This pre-formed structure maintains desired strength while dramatically reducing formation time from manual weaving to automated installation.
Solution Approach 2:
The patent replaces manual mechanical weaving with automated braiding machinery. The braided loop is created using automated braiders that can continuously form loops without manual intervention, substituting the time-consuming manual process of crossing and manipulating filaments with automated mechanical systems that produce identical or superior braided structures more efficiently.
2Shape
If multiple separate filaments are used manually, then desired braid pattern can be achieved, but manufacturing complexity and costs increase
Solution Approach 1:
The patent applies preliminary action by pre-determining the exact braid pattern, filament arrangement, and loop configuration during manufacturing. The braided structure is created with predetermined geometry and pattern before leaving the factory, eliminating complex manual manipulation during surgery. This pre-configured approach simplifies the overall system while maintaining precise braid patterns.
Solution Approach 2:
The patent replaces complex manual filament manipulation with automated braiding equipment. The automated braiders use programmed mechanisms to precisely control filament crossing, wrapping, and arrangement, creating consistent braid patterns without human error. This automation reduces manufacturing complexity by eliminating the need for skilled manual weavers and standardizes the production process.
3Manufacturing precision
If filaments are manually woven back and forth, then desired length and thickness can be achieved, but the process is susceptible to imperfections from user error
Solution Approach 1:
The patent replaces manual filament weaving with automated braiding machinery that provides consistent, repeatable results. The automated systems use precise mechanical controls to ensure uniform filament thickness, consistent braid spacing, and uniform loop dimensions throughout the entire structure. This eliminates variability introduced by manual operations while maintaining the desired length and thickness.
Solution Approach 2:
The patent incorporates feedback mechanisms in the automated braiding process to monitor and adjust filament tension, spacing, and alignment in real-time. Sensors detect deviations from the target configuration and automatically adjust the braiding parameters to maintain precision. This closed-loop control ensures consistent loop quality without the imperfections inherent in manual weaving.
4Strength
If separate filaments are used, then braided configuration can be formed, but material management becomes difficult and costs increase
Solution Approach 1:
The patent merges multiple separate filaments into a single integrated braided structure during automated manufacturing. Rather than managing multiple independent filament supplies and manually handling each strand, the automated braider processes all filaments simultaneously as a unified assembly. This merging simplifies material management while maintaining the combined strength of multiple filaments in the final braided product.
Data Source
AI summary
Devices and systems for use in soft tissue repair are provided, as are methods of manufacturing the same. In one exemplary embodiment, an implantable surgical construct includes an implant and a continuous braided closed filament loop that is attached to the implant. The continuous loop can be formed from a single strand of filament such that portions of the filament, sometimes referred to as tails, can be arranged with respect to each other to form a braided configuration. A related method of manufacture can involve passing portions of a single strand of filament around different sets of posts and selectively over and under each other to create the braided configuration. Other devices, systems, and methods of manufacturing are also provided, including some that involve using multiple strands of suture to form a continuous braided closed filament loop.