Corner-Lock Implant Mesh Stitching for Stable Pore Geometry
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Solution Overview
Problem
Existing biotextiles face issues with stretching and deformation of pores due to wide voids between stitch patterns, leading to potential herniation of body tissue through the mesh, particularly in medical applications.
Innovation Solution
The implementation of corner-lock stitch patterns, which involve overlapping threads at angles or curves with interlace points and thread overlays, forming a mesh that resists deformation and maintains pore shape under tension.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If standard lockstitch patterns are used in biotextiles, then the material can be joined and reinforced, but the wide voids between stitch patterns allow stretching and deformation of pores under tension
Solution Approach 1:
The stitching pattern is segmented into multiple intersecting lines that form a grid-like structure with corner-lock stitches at intersections. This segmentation creates smaller, more numerous stable regions throughout the mesh, preventing large-scale pore deformation while maintaining overall mesh integrity.
Solution Approach 2:
Corner-lock stitches are placed at the vertices of the mesh pattern in advance, creating pre-reinforced anchor points before tension is applied. These preliminary corner-lock stitches prevent the pores from deforming under load by establishing stable reference points that resist stretching.
2Stability of the object's composition
If stitch density is increased to reduce pore deformation, then pore shape stability improves, but the complexity of the stitching pattern and manufacturing difficulty increase
Solution Approach 1:
Instead of uniformly increasing stitch density across the entire mesh, the corner-lock stitch technique applies enhanced reinforcement locally at the vertices where pores intersect. This localized quality improvement provides maximum pore shape stability at critical points without requiring complex stitching throughout the entire structure.
Solution Approach 2:
The stitching system combines two different stitch types: standard lockstitches for general reinforcement and corner-lock stitches for critical vertex reinforcement. This composite stitching approach creates a hierarchical structure that optimizes both pore shape stability and manufacturing simplicity by applying different stitch complexities where needed.
3Reliability
If corner-lock stitch patterns are implemented, then pore deformation is prevented and mesh integrity is maintained, but the stitching time and manufacturing complexity increase
Solution Approach 1:
The corner-lock stitch technique applies reinforcement selectively at vertex points rather than continuously across all edges. This partial action approach provides sufficient reinforcement to prevent pore deformation at critical locations without the excessive stitching required for complete edge reinforcement, thereby maintaining productivity.
Solution Approach 2:
The corner-lock stitch creates a curved, enveloping pattern around the vertex point rather than a straight linear stitch. This curved configuration provides superior mechanical resistance to pore deformation through geometric distribution of stress, achieving higher reliability with fewer stitches compared to linear patterns.
Data Source
AI summary
Implants with corner-lock stitch patterns. The implants may include a substrate having a mesh formed therein. The mesh may include a corner-stitch pattern where a second stitch pattern interlaces with corners of a first stitch pattern. The first stitch pattern may include a first upper thread and a first lower thread that are sewn into the substrate at a first corner. The second stitch pattern may include a second upper thread and a second lower thread that envelop the first upper thread and the first lower thread adjacent to the first corner.