Planar Heater Assembly for Knot-Free Suture Welding

Solution Overview

Problem

Surgical sutures often require knots or loop-closing devices for securing wounds, which can be problematic in delicate or restricted areas, and existing fusion methods may not provide sufficient strength or controlled heat for reliable welding.

Innovation Solution

A heater device with a substrate and heater element designed for controlled heat application to thermally weld suture strands, featuring a planar heater support surface, joinder layer, and electrical interface for precise temperature control, allowing for secure suture welds without knots or loop-closing devices.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If knots or loop-closing devices are used to secure suture wounds, then the suture can be reliably secured, but the procedure becomes more complex and is problematic in delicate or restricted areas

Engineering Contradiction:

Improvesuture securityVSAvoidknot or loop-closing device

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts the knot-tying function entirely from the suturing process by using a heater assembly to thermally fuse the suture material itself. The heater assembly applies controlled heat to melt and bond the suture strands together, eliminating the need for separate knot-securing devices and simplifying the overall surgical procedure while maintaining reliability in delicate or restricted areas

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent replaces the mechanical knot-tying system with a thermal fusion system. Instead of using mechanical friction and tension from knots or loop-closing devices, the heater assembly uses controlled thermal energy to melt and fuse the suture material, creating a secure bond without mechanical complexity

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

2Ease of operation

If existing fusion methods are used to weld suture strands, then knot-free securing is achieved, but sufficient strength or controlled heat for reliable welding is not provided

Engineering Contradiction:

Improveknot-free securingVSAvoidweld strength

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The heater assembly incorporates feedback control through its temperature-controlled heating element that monitors and adjusts the heat applied to the suture material. This ensures the temperature remains within the optimal range for melting and fusing the suture without overheating or underheating, providing consistent and reliable weld strength while maintaining ease of operation

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent applies controlled changes in temperature parameters to achieve reliable suture welding. The heater assembly maintains specific temperature ranges that optimize the melting and fusing of suture materials, transforming the fusion process from unreliable to dependable while keeping the procedure simple and knot-free

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If existing fusion methods are used to weld suture strands, then knot-free securing is achieved, but controlled heat for reliable welding is not provided

Engineering Contradiction:

Improveknot-free securingVSAvoidheat control

Core Design Contradiction:

Ease of operationVSTemperature

Solution Approach 1:

The heater assembly incorporates feedback control through its temperature-controlled heating element that monitors and adjusts the heat applied to the suture material. This ensures the temperature remains within the optimal range for melting and fusing the suture without overheating or underheating, providing consistent and reliable weld strength while maintaining ease of operation

Inventive Principle:

Principle #23Feedback

Solution Approach 2:

The patent applies controlled changes in temperature parameters to achieve reliable suture welding. The heater assembly maintains specific temperature ranges that optimize the melting and fusing of suture materials, transforming the fusion process from unreliable to dependable while keeping the procedure simple and knot-free

Inventive Principle:

Principle #35Parameter changes

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

Enables reliable and controlled heat application for secure suture welds, particularly suited for endoscopic surgery, providing consistent strength and proximity for wound healing without the need for knots or additional devices.

Implementation Method 1

portions of one or more segments to be joined together are fused in a welding process to form a welded joint

Methodology Applied

Scientific EffectJoule heating: Joule Heating

Implementation Method 2

cause partial melting and fusion of the sections

Methodology Applied

Scientific EffectMelting: Melting

Data Source

PatentUS8592730B2Heater assembly for suture welder

Publication Date: 2013.11.26 HOWMEDICA OSTEONICS CORP

AI summary

Disclosed is a heater device for thermally welding suture strands, including: a substrate extending from a first end to a second end along a substrate axis, and having a substantially planar heater support surface; a joinder layer disposed on the heater support surface; a heater element extending from a first end to a second end along a heater axis thereof and disposed on the joinder layer, the heater element being a layer and being coupled to the support surface by the joinder layer; an electrical interface including a first electrically conductive element coupled to the first end of the heater element, and a second electrically conductive element coupled to the second end of the heater element. In some embodiments, the heater element is elongated along the heater axis.