Knotless Suture Package with Circular Loading Unit
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Solution Overview
Problem
Existing suture packages struggle to precisely position surgical needles for minimally invasive procedures and accommodate barbed suture material without entanglement, especially in compact packaging scenarios.
Innovation Solution
A suture package design featuring a circular body with a loading unit secured by tabs and slots, a U-shaped suture tray, and a cover with a ring for secure engagement, which supports the surgical needle and barbed suture material, preventing entanglement and facilitating precise alignment with surgical suturing apparatuses.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If the surgical needle is held loosely within the packaging to allow for manipulation, then the ease of operation is improved, but the manufacturing precision and positioning accuracy deteriorate
Solution Approach 1:
The packaging is divided into distinct functional zones: a loading unit with precision positioning features (slots, tabs, rails) for accurate needle placement, and a separate suture tray area for suture material storage. This segmentation allows the needle to be precisely positioned during loading while maintaining operational flexibility during use.
Solution Approach 2:
The loading unit incorporates movable components including a movable plate that can shift between locked and unlocked positions, and a suture retrieval mechanism that dynamically adjusts as suture is pulled through. This dynamic design enables precise initial positioning that transitions to operational flexibility during surgical use.
2Volume of stationary object
If the suture material is wrapped compactly to conserve space, then the volume of packaging is reduced, but the barbs become entangled and foul with each other
Solution Approach 1:
The suture material is extracted from traditional wrapped configurations and placed in a dedicated suture tray with a controlled layout. The barbed suture is arranged in a specific pattern within the tray that prevents barb-on-barb contact, eliminating entanglement while maintaining compact packaging volume.
Solution Approach 2:
The suture tray acts as an intermediary structure between the compact packaging requirement and the need to prevent barb entanglement. The tray's specific geometry and surface features provide separation and organization for the barbed suture, allowing compact storage without contact between barbs.
3Reliability
If the loading unit is securely attached to the body portion to ensure stability, then the reliability is improved, but the device complexity increases
Solution Approach 1:
The loading unit is merged with the body portion through an integrated attachment mechanism. The movable plate and suture tray are combined into a single unified structure that attaches to the body portion through a simple locking mechanism, achieving stability without adding significant structural complexity.
Solution Approach 2:
The loading unit incorporates self-aligning and self-locking features that automatically ensure proper positioning and attachment without requiring complex external fastening mechanisms. The slots, tabs, and rails work together as a self-contained system that provides stable attachment through its own geometric features.
Data Source
AI summary
Various embodiments of suture packages are disclosed to provide a surgical needle, having an associated length of suture material, to a surgical suturing instrument. The disclosed suture packages generally include a body portion having a needle supplying loading unit mounted thereon. Various methods of affixing the loading unit to the body portion are disclosed. The body portion defines a suture tray and a cover is provided to secure a suture within the suture tray. A securing ring is provided to secure the cover to the body portion.