Filament Winding Biocompatible Mesh Pore Control
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Solution Overview
Problem
Existing methods for creating biocompatible meshes for soft tissue repair and implantable slings for female stress urinary incontinence lack the ability to produce macroporous fabrics with controllable pore size and efficient use of biocompatible threads, particularly collagen threads, which are not optimally aligned with the load axis.
Innovation Solution
A system utilizing a microprocessor, a support surface with pins, and a spool of biocompatible filament with a tensioner to custom manufacture an implantable macroporous mesh. The system optimizes filament usage, controls pore size, and aligns filaments approximately to the load axis through precise winding and treatment with a biocompatible solution to bond intersecting filament sections.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If traditional weaving or knitting methods are used to create biocompatible mesh, then the mesh can be formed with interlaced threads, but the thread consumption is excessive and the threads are not optimally aligned with the load axis
Solution Approach 1:
The patent employs a filament winding process that creates a macroporous structure by winding biocompatible threads in a spiral pattern around a mandrel, forming a mesh with controlled pore size and shape. This approach eliminates the need for traditional weaving or knitting interlacing, significantly reducing thread consumption while maintaining structural integrity and optimal alignment with the load axis
Solution Approach 2:
The patent uses a spiral winding configuration around a mandrel, creating a curved, helical pattern of thread placement. This curved arrangement allows the threads to be optimally aligned with the load axis while forming a macroporous structure, avoiding the excessive thread consumption associated with traditional weaving or knitting methods
2Loss of substance
If filament winding is used to minimize thread usage and improve alignment, then thread efficiency increases, but the ability to control pore size and create macroporous structure is limited
Solution Approach 1:
The patent employs a computer-controlled filament winding system that dynamically adjusts winding parameters including spiral angle, winding speed, and tension to precisely control pore size and macroporous structure. This dynamic control enables optimization of both thread efficiency and pore size control, resolving the contradiction between minimizing thread usage and achieving precise pore size control
Solution Approach 2:
The patent utilizes computer-controlled adjustment of multiple winding parameters including spiral angle, winding speed, tension, and mandrel rotation speed to precisely control the pore size and macroporous structure. By dynamically changing these parameters during the winding process, the system achieves both high thread efficiency and precise pore size control
3Reliability
If biocompatible threads are used for implantable devices, then biocompatibility is achieved, but the mechanical strength and structural integrity may be compromised
Solution Approach 1:
The patent employs biocompatible threads made from materials such as polyglycolic acid, polylactic acid, or collagen, which provide both biocompatibility and adequate mechanical strength. The spiral winding configuration and computer-controlled tension application create a macroporous mesh structure that optimizes the mechanical properties of these biocompatible materials, achieving both biocompatibility and structural integrity
Data Source
AI summary
A system and method for determining a mesh layout and manufacturing an implantable mesh. A support surface with pins is provided in a configuration that corresponds to the mesh layout. A biocompatible filament is wound around the pins to provide a macroporous mesh. The completed weave is treated with a solution to bond intersection points of filament, then sterilized and packaged to provide an implantable mesh.