One-Piece Knitted T Prosthesis Without Weak Join Points
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Solution Overview
Problem
Existing T-shaped prostheses for reinforcing the abdominal wall after incision have weaknesses at the join between the vertical and horizontal bars, which can lead to tearing under pressure and tension, and their production methods are complex and prone to discontinuities.
Innovation Solution
A T-shaped knitted prosthesis made in one piece using a warp knitting machine with biocompatible yarns, where a base sheet with perpendicular folds forms both the horizontal and vertical components, eliminating the need for joining and creating a continuous structure without weaknesses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If two separate sheets of material are joined to form a T-shaped prosthesis, then the prosthesis can be assembled from modular components, but the join between sheets creates a point of weakness that may tear under pressure and tension
Solution Approach 1:
The patent merges two separate sheets into a single knitted structure formed in one piece. The T-shaped prosthesis is created by knitting a base sheet and then forming perpendicular folds directly from the same continuous yarns, eliminating the need to join separate components and removing weak join points.
Solution Approach 2:
The patent uses segmentation in reverse by creating apparent segmentation (the T-shape with perpendicular bars) through folding a single continuous knitted sheet rather than joining separate pieces. The perpendicular folds create the visual and functional segmentation of the T-shape while maintaining material continuity.
2Shape
If joining methods such as sewing or thermal welding are used to connect sheets, then the T-shape can be formed, but the joining process creates discontinuities and potential weak points in the prosthesis
Solution Approach 1:
The patent combines the shape-forming function and the structural continuity function into a single process. The T-shape is formed by creating perpendicular folds in the knitted sheet through controlled variations in yarn tension and knitting pattern, while the continuous knitted structure maintains compositional stability throughout.
Solution Approach 2:
The patent replaces mechanical joining systems (sewing needles, thermal welding equipment) with a knitting system that forms the T-shape through controlled yarn manipulation. The knitting machine creates the perpendicular folds by varying the tension and routing of yarns during the knitting process itself, eliminating the need for separate joining operations.
3Reliability
If openworked material is used to promote cell recolonization, then biocompatibility is improved, but the material may be more susceptible to tearing at join points
Solution Approach 1:
The patent merges the biocompatibility function and the strength function into a single continuous openworked knitted structure. The same openworked material that promotes cell recolonization throughout the prosthesis maintains consistent structural integrity because there are no join points where the material continuity is disrupted.
4Strength
If a single-piece knitted structure is produced, then continuous strength throughout the prosthesis is achieved, but the production process requires complex knitting machine operations
Solution Approach 1:
The patent uses dynamic control of the knitting machine to produce the T-shape from a single sheet. The knitting machine dynamically adjusts yarn tension, needle selection, and stitch formation during the knitting process to create the perpendicular folds and T-shape configuration, all while maintaining continuous material flow and structural integrity.
Data Source
AI summary
The invention relates to a method for producing a prosthesis comprising a knitted structure made in one piece, in which method a knit (1) comprising a base sheet (2) and a succession of perpendicular folds (3) is produced in a single knitting step, and said knit (1) is then cut on each side of said folds (3) in order to obtain said knitted structure.