Lightweight Hernia Mesh Fabric with Titanium Metallization
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Solution Overview
Problem
Current hernia mesh implants made from plastic materials like polyester, PTFE, and polypropylene often cause inflammatory responses and mechanical strain, leading to complications and recurrence, necessitating a mesh fabric with improved tolerance and reduced foreign body reaction.
Innovation Solution
A lightweight, single-layered hernia mesh fabric with a basis weight of 5 to 40 g/m2, made from monofilament or multifilament polypropylene threads with surface metallization using PACVD processes, providing excellent tissue tolerance and flexibility, and manufactured using warp-knit techniques with specific mesh densities and porosity for optimal fit and adhesion.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional plastic mesh fabric is used for hernia repair, then the implant provides structural support, but it causes inflammatory responses and foreign body reactions
Solution Approach 1:
The patent changes the physical and chemical parameters of the mesh fabric by reducing basis weight from conventional values to 5-40 g/m2, using monofilament construction instead of multifilament, and applying titanium metallization to the surface. These parameter changes transform the biological response from inflammatory to tolerant, resolving the contradiction between structural support and reduced inflammatory response.
Solution Approach 2:
The patent creates a composite structure by combining plastic monofilament threads with titanium metallization coating. This composite material approach allows the base plastic material to provide structural support while the titanium surface layer provides biocompatibility and reduced foreign body reaction, simultaneously addressing both requirements.
2Object-affected harmful factors
If the basis weight of mesh fabric is reduced to 5-40 g/m2, then tissue tolerance improves and flexibility increases, but mechanical strength may be compromised
Solution Approach 1:
The patent applies different properties to different parts of the mesh structure: the core plastic monofilament provides mechanical strength and structural integrity, while the titanium metallization layer provides biocompatibility and surface properties. This local differentiation allows the lightweight structure to maintain both strength and tissue tolerance.
Solution Approach 2:
The mesh fabric is constructed from individual monofilament threads rather than bundled multifilaments, creating a segmented structure. This segmentation allows each thin monofilament to be individually metallized and positioned, maintaining overall mechanical strength through the woven pattern while reducing total material quantity to minimize foreign body reaction.
3Object-affected harmful factors
If monofilament threads are used instead of multifilament, then tissue tolerance improves, but manufacturing complexity increases
Solution Approach 1:
The patent uses warp-knit hosiery machines that are versatile enough to produce both the mesh fabric structure and apply the titanium metallization coating in a integrated process. This multi-functional manufacturing approach handles the complexity of monofilament production and metallization through a single universal equipment system, reducing overall manufacturing complexity.
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 lightweight, flexible mesh fabric reduces irritation and rejection, adheres well to body surfaces, and provides long-term results with minimal recurrence, facilitated by its low material quantity, titanium metallization, and laser-cutting to prevent thread unraveling.
Implementation Method 1
Surface metallization of the threads in particular with titanium offers excellent tissue tolerance. Metallizations of this kind, which are based on the use of PACVD processes
Implementation Method 2
laser-cutting to prevent thread unraveling
Data Source
AI summary
The invention relates to a flat implant of textile thread material, in particular a hernia mesh implant, in the form of single-layered mesh fabric (1) of a basis weight of 5 to 40 g/m2.