Gradient-Density Melt-Blown Hemostatic Patch for Coating Penetration
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Solution Overview
Problem
Existing absorbable hemostatic patches lack efficient coating penetration and distribution of cross-linkable active molecules, compromising their hemostatic effectiveness and malleability during surgical procedures.
Innovation Solution
A multi-layered, melt-blown nonwoven substrate with a descending density and ascending porosity gradient, allowing deep penetration and uniform distribution of cross-linkable active molecules, enhancing hemostatic performance and conformability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a uniform-density substrate is used, then the structure is simple to manufacture, but the coating penetration and distribution of active molecules is insufficient
Solution Approach 1:
The substrate is constructed with a density gradient where the top layer has lower density (higher porosity) to facilitate coating penetration and active molecule distribution, while the bottom layer has higher density to provide structural support. This local variation in density optimizes both coating absorption and structural integrity without requiring complex manufacturing processes.
Solution Approach 2:
The substrate combines multiple materials or layers with different density characteristics to create a composite structure. The top layer uses a more porous, less dense material to enhance coating penetration, while the bottom layer uses a denser material for strength, creating a functionally optimized composite substrate.
2Manufacturing precision
If the substrate porosity is increased to improve coating penetration, then the coating distribution improves, but the structural strength decreases
Solution Approach 1:
The substrate employs a porosity gradient where the top layer has high porosity (30-80%) to enable deep coating penetration and uniform active molecule distribution, while the bottom layer has lower porosity (10-30%) to maintain structural strength and stability during surgical procedures.
Solution Approach 2:
The substrate is constructed as a composite of layers with different porosity levels. The upper layer uses a highly porous structure to maximize coating absorption, while the lower layer uses a less porous, stronger material to provide mechanical support, creating a composite that balances both requirements.
3Strength
If the substrate density is increased to improve structural stability, then the strength improves, but the coating penetration depth decreases
Solution Approach 1:
The substrate features a density gradient where the top layer has low density to allow coating and active molecules to penetrate deeply into the substrate matrix, while the bottom layer has high density to provide structural stability and prevent substrate deformation during surgical use.
4Reliability
If a multi-layered gradient substrate is used, then the hemostatic effectiveness is improved, but the manufacturing complexity increases
Solution Approach 1:
The substrate is divided into multiple discrete layers (typically 3-5 layers) with progressively varying density and porosity characteristics. Each layer is optimized for a specific function: top layers for coating penetration and active molecule distribution, middle layers for transition and support, and bottom layers for structural stability. This segmentation allows standard manufacturing processes to create a complex gradient structure.
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
The gradient-based substrate achieves effective hemostasis with improved coating penetration, tissue adhesion, and malleability, suitable for both open and minimally invasive surgeries, with enhanced deployment and adhesion properties.
Implementation Method 1
melt-blown nonwoven microfibers as webbed sheets that are layered and bonded/entangled
Data Source
AI summary
The present invention is directed to an absorbable hemostatic nonwoven patch that utilizes a biocompatible substrate comprised of melt-blown microfibers as webbed sheets that are layered and bonded/entangled in descending density and ascending porosity; with the substrate having a high flexibility, strength and porosity that is suitable for coating cross-linkable active molecules and ability for laparoscopic use or trocar deployment, ultimately for functional use as a highly effective hemostat in addressing problematic bleeding during both open and minimally invasive surgical procedures.