Hernia Mesh with Variable Thread Thickness for Unfoldability
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Solution Overview
Problem
Hernia meshes with low basis weight made from thin monofilament threads face difficulties in unfolding within the abdominal cavity due to low resilience, while stiffer meshes with larger area weight can provoke unwanted defense reactions and scarring, necessitating a balance between rigidity and foreign material minimization.
Innovation Solution
A planar hernia mesh with a combination of thicker and thinner non-resorbable monofilament threads, where the thicker threads provide necessary rigidity and the thinner threads reduce foreign material, with heat-setting and reinforcement strips to enhance unfoldability and minimize fraying, and an anisotropic structure achieved by varying thread arrangements and materials like polypropylene, polyurethane, or polyethylene terephthalate.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If hernia meshes with low basis weight made from thin monofilament threads are used, then the amount of foreign material is reduced, but the mesh has poor elasticity and does not unfold easily after insertion
Solution Approach 1:
The patent applies local quality by creating regions of different thread thicknesses within the same mesh structure. Thinner threads are used in areas where minimal foreign material is desired, while thicker threads are strategically placed to provide elasticity and promote unfolding. This local variation in thread diameter allows the mesh to simultaneously reduce overall foreign material while maintaining sufficient unfoldability in critical regions.
2Strength
If stiffer meshes with larger area weight are used, then rigidity for implantation is improved, but unwanted defense reactions and scarring increase
Solution Approach 1:
The patent implements local quality by using thicker threads only in specific regions where rigidity is needed for implantation handling, while the majority of the mesh uses thinner threads to minimize foreign material and reduce scarring. This localized approach to thread thickness allows the mesh to have sufficient rigidity for surgical manipulation without excessive stiffness that would trigger strong defense reactions.
Solution Approach 2:
The patent applies parameter changes by varying the thread diameter parameter within the mesh structure. By changing the thread thickness parameter from uniform to variable, the mesh achieves different mechanical properties in different regions - thicker threads provide rigidity where needed, while thinner threads reduce overall material mass and foreign body reaction.
3Strength
If threads of different thicknesses are used throughout the entire mesh, then stiffness is improved, but the amount of foreign material increases
Solution Approach 1:
The patent resolves this contradiction by applying different thread thicknesses locally rather than uniformly throughout the entire mesh. Thicker threads are placed only in specific regions where additional stiffness is beneficial, while the majority of the mesh uses thinner threads to minimize foreign material. This selective approach ensures stiffness is provided only where necessary.
Solution Approach 2:
The patent applies partial action by using thicker threads only partially in the mesh structure, specifically in regions where rigidity is needed for implantation, rather than using thick threads throughout the entire mesh. This partial application of thicker threads provides sufficient stiffness without the excessive foreign material burden that would result from uniform thick threading.
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 mesh achieves improved unfoldability and reduced foreign material presence, minimizing scarring and defense reactions, while maintaining sufficient rigidity for implantation, with adjustable properties and reduced weight through strategic thread placement and material selection.
Implementation Method 1
The nets according to the invention are generally heat-set. This prevents, among other things, unwanted fraying. The heat setting is carried out on the tensioned net by heating it to temperatures below the softening range of the polymer material.
Implementation Method 2
Stiffeners, which can be provided in addition to or instead of the thicker threads, can also be formed by reinforcing the heat setting in strips and sintering the monofilament threads together, particularly at intersection points.
Data Source
Figure 1
Figure 2
Figure 3~5
AI summary
The invention relates to a flat implant, particularly a hernia mesh, which has the form of a textile net (1) with an opening (2) and consists of non-resorbable monofil threads. The net (1) comprises threads of different thicknesses (3, 4), which run parallel to one another.