Perforated Collagen-Coated Surgical Mesh Manufacturing
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Solution Overview
Problem
Existing methods for producing collagen-coated meshes often result in fluid pockets, damage to the mesh surface, and difficulty in controlling coating thickness and porosity, which can impede tissue integration and mechanical strength.
Innovation Solution
A method involving positioning needles through the mesh pores, coating with collagen, freezing, and drying to create perforated collagen-coated meshes with controlled thickness and porosity, preventing fluid pocket formation and maintaining mesh integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the mesh is completely coated with collagen, then cell attachment and tissue in-growth are improved, but fluid pockets form between the implant and soft tissue
Solution Approach 1:
The patent applies porous materials by creating perforations through the collagen coating that extend through the entire coating thickness. These perforations allow fluid drainage while maintaining the collagen coating's integrity for tissue in-growth. The porous structure is achieved by forming channels that penetrate the coating, enabling simultaneous fluid evacuation and biological integration.
Solution Approach 2:
The patent segments the collagen coating by creating multiple perforations that divide the continuous coating into sections with fluid drainage pathways. This segmentation allows fluid pockets to be drained while preserving the coating's functional integrity for cell attachment and tissue integration.
2Manufacturing precision
If gas stream is used to remove collagen from pores, then perforations are created, but too much or too little collagen is stripped and thickness control is difficult
Solution Approach 1:
The patent applies preliminary action by pre-positioning spacers or inserts within the mesh pores before applying the collagen coating. These pre-placed spacers define the exact thickness and location of the collagen layer, eliminating the need for post-coating thickness adjustment or gas stream removal.
Solution Approach 2:
The patent uses spacers or inserts as intermediary elements that mediate between the mesh substrate and the collagen coating. These intermediaries physically define the coating thickness and facilitate controlled collagen application, replacing the uncontrolled gas stream removal process.
3Manufacturing precision
If the collagen coated fabric is perforated after drying, then perforations are formed, but damage occurs to the underlying fabric resulting in decreased mechanical strength
Solution Approach 1:
The patent applies preliminary action by creating perforations in the mesh substrate before applying the collagen coating. This ensures that the perforations are formed in the weaker substrate material rather than through the stronger coated surface, preventing damage to the fabric while achieving the desired perforated structure.
Solution Approach 2:
The patent inverts the conventional sequence by forming perforations in the mesh before coating, rather than perforating the coated surface. This reversal of the process sequence prevents mechanical damage to the fabric while achieving the same functional outcome of fluid drainage.
4Ease of manufacture
If dip coating or spray coating is used, then collagen solution is applied to mesh surface, but only surface coating is achieved without penetrating into the mesh
Solution Approach 1:
The patent applies preliminary action by pre-wetting or pre-opening the mesh pores before collagen coating. This preparation step creates pathways that allow the collagen solution to penetrate deep into the mesh structure rather than forming only a surface coating, achieving uniform distribution throughout the mesh.
Solution Approach 2:
The patent changes the physical parameters of the mesh (such as pore size, wettability, or porosity) before coating to facilitate collagen penetration. By modifying these parameters, the collagen solution can infiltrate the mesh structure deeply, achieving both surface and internal coating.
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 method allows for the production of perforated collagen-coated meshes that minimize fluid pocket formation, enhance tissue integration, and maintain the mechanical properties of the mesh, facilitating better healing and repair in soft or hard tissue applications.
Implementation Method 1
freezing the coated mesh
Implementation Method 2
drying the collagen coated mesh
Data Source
Figure 1A~1B
Figure 1C~1D
Figure 2A~2B
AI summary
Methods to produce perforated collagen coated meshes for use as implants have been developed. The method involves positioning needles through the pores of the mesh, coating the mesh with a collagen solution, freezing the coated mesh, removing the needles from the frozen coated mesh, drying the collagen coated mesh, and optionally cross-linking the coated mesh. The method allows perforated collagen coated meshes to be prepared with variable thickness, and without damage to the surface of the mesh. The perforations of the collagen coated meshes may be designed to prevent the formation of fluid pockets when the coated meshes are implanted, and to permit rapid incorporation into host tissue. The perforated collagen coated meshes may be used for soft tissue repair, regeneration or remodeling including, for example, hernia repair, mastopexy, treatment of urinary incontinence, pelvic floor reconstruction, and ligament and tendon repair.