Electrospun Prosthetic Valve Manufacturing via Rotating Mold

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Solution Overview

Problem

Current methods for manufacturing prosthetic valves are laborious, expensive, and time-consuming, as they involve manually suturing animal tissue onto stent-like frames, resulting in significant tissue waste and low yields.

Innovation Solution

The method involves using an electrospinning process to create prosthetic valves from biocompatible artificial fibers. A prosthetic valve mold is rotated at specific angles and velocities to deposit layers of electrospun fibers, forming a valve with a radially expanded and compressed configuration, and a lumen for flow regulation.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If manual suturing of animal tissue onto stent-like frames is used, then prosthetic valves can be manufactured, but the process is laborious, expensive, and time-consuming with significant tissue waste

Engineering Contradiction:

Improvemanufacturing processVSAvoidmanufacturing time

Core Design Contradiction:

Ease of manufactureVSProductivity

Solution Approach 1:

The patent replaces the manual mechanical suturing process with an automated electrospinning system that deposits biocompatible fibers onto stent-like frames. This substitution eliminates the need for hand-sewing operations, significantly reducing labor intensity and manufacturing time while improving consistency and yield.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the material parameter from animal tissue to biocompatible artificial fibers produced through electrospinning. This parameter change enables automated manufacturing processes, improves material utilization efficiency, and eliminates the waste associated with manual tissue preparation and suturing.

Inventive Principle:

Principle #35Parameter changes

2Reliability

If animal tissue is used for prosthetic valves, then the valves can be manufactured, but most of the animal tissue is discarded and wasted

Engineering Contradiction:

ImprovebiocompatibilityVSAvoidtissue waste

Core Design Contradiction:

ReliabilityVSLoss of substance

Solution Approach 1:

The patent changes the material parameter from animal tissue to biocompatible artificial fibers. This substitution maintains the essential biocompatibility requirement while enabling precise control over material usage, eliminating the significant waste that occurs during manual tissue preparation and application.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent creates artificial fiber copies that replicate the functional properties of animal tissue without requiring actual biological material. These electrospun fibers are deposited in controlled patterns onto the stent frame, providing the necessary biocompatibility and structural properties without the waste inherent in using real animal tissue.

Inventive Principle:

Principle #26Copying

3Ease of manufacture

If manual suturing processes are used, then prosthetic valves can be assembled, but the process is tedious and time-consuming

Engineering Contradiction:

Improveassembly processVSAvoidmanufacturing time

Core Design Contradiction:

Ease of manufactureVSLoss of time

Solution Approach 1:

The patent replaces the manual mechanical suturing process with an automated electrospinning system. The electrospinning apparatus automatically deposits fibers onto the stent frame in a controlled manner, eliminating the tedious hand-sewing operations that significantly extend manufacturing time.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent performs preliminary fiber preparation and deposition before final assembly is needed. The biocompatible fibers are pre-formed through electrospinning and then applied to the stent frame, eliminating the need for time-consuming manual suturing operations during the final assembly process.

Inventive Principle:

Principle #10Preliminary action

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 reduces waste, lowers manufacturing costs and time, and improves yields by eliminating the need for manual suturing and utilizing biocompatible artificial materials, while also allowing for precise control of material properties.

Implementation Method 1

A first layer of a first plurality of electrospun fibers is deposited on to an outer surface of the prosthetic valve mold

Methodology Applied

Scientific EffectElectrospinning: Electrohydrodynamics

Implementation Method 2

A second layer of a second plurality of electrospun fibers is deposited on an outer surface of the rotating frame and an outer surface of the first layer

Methodology Applied

Scientific EffectElectrospinning: Electrohydrodynamics

Data Source

PatentUS12201516B2Electrospun medical devices and methods of making electrospun medical devices

Publication Date: 2025.01.21 MEDTRONIC INC

AI summary

A method of forming an electrospun prosthetic valve includes utilizing a rotatable and angularly adjustable prosthetic valve mold. The prosthetic valve mold is set to a first angle. The prosthetic valve mold is rotated at a first rotational velocity and a first layer of electrospun fibers is deposited on the prosthetic valve mold. The prosthetic valve mold is stopped and a frame is positioned over the first layer. The prosthetic valve mold is set to a second angle. The prosthetic valve mold is rotated at a second velocity and a second layer of electrospun fibers is deposited on an outer surface of the first layer and an outer surface of the frame.