Rotary Retainer Forming Apparatus for Self-Retaining Sutures

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Conventional sutures face issues such as suture breakage, knot slippage, infection, and excessive inflammatory response due to knots, and self-retaining sutures have not achieved significant clinical success in overcoming these deficiencies.

Innovation Solution

A rotary retainer forming apparatus and method that includes a blade with a cutting edge directed inward to form retainers on a continuous suture strand, allowing for various retainer configurations with high output efficiency and minimal setup or changeover, using a support member and feed mechanism to rotate and twist the suture for precise cutting.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If conventional sutures with knots are used, then suture strength is maintained, but suture breakage, knot slippage, and inflammatory response occur

Engineering Contradiction:

Improvesuture reliabilityVSAvoidinflammatory response

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The patent removes the harmful knots from the suture system while maintaining suture function through self-retaining barbed retainers that anchor tissue without requiring knots, thereby eliminating knot-related complications such as slippage, breakage, and inflammatory response

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The patent converts the potential harm of knot-related complications into benefit by using barbed retainers that provide secure tissue anchoring without knots, transforming the design to eliminate harmful effects while maintaining or improving suture reliability

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

2Productivity

If linear reciprocating cutting devices are used to form retainers, then retainers can be formed on sutures, but output efficiency is limited

Engineering Contradiction:

Improveretainers per secondVSAvoidapparatus complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

The patent transitions from static or reciprocating cutting devices to a dynamic rotary blade system that continuously rotates to cut retainers on moving sutures, dramatically increasing output efficiency from limited reciprocating motion to high-speed continuous operation

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The rotary blade operates continuously as sutures pass through the apparatus, eliminating the stop-start nature of reciprocating devices and maintaining continuous cutting action to maximize retainer formation speed and productivity

Inventive Principle:

Principle #20Continuity of useful action

3Adaptability or versatility

If multiple retainer configurations are required, then surgical preferences can be met, but apparatus setup and changeover time increases

Engineering Contradiction:

Improveretainer configuration varietyVSAvoidsetup and changeover time

Core Design Contradiction:

Adaptability or versatilityVSLoss of time

Solution Approach 1:

The rotary blade apparatus is designed to perform multiple functions by adjusting blade position, angle, and rotation speed to create various retainer configurations including unidirectional, bidirectional, and helical patterns, allowing one apparatus to replace multiple specialized devices

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The apparatus uses dynamic adjustment of blade parameters during operation to switch between different retainer configurations without physical changeover, allowing real-time adaptation to different surgical requirements while maintaining continuous production

Inventive Principle:

Principle #15Dynamics

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 apparatus efficiently forms retainers on sutures with high output, enabling countless configurations and reducing the need for knots, thereby minimizing suture slippage and inflammatory responses, enhancing surgical efficacy.

Implementation Method 1

a blade with a cutting edge directed inward to form retainers on a continuous suture strand

Methodology Applied

Scientific EffectMechanical cutting: Fracture Mechanics

Implementation Method 2

using a support member and feed mechanism to rotate and twist the suture for precise cutting

Methodology Applied

Scientific EffectRotational motion:

Data Source

PatentUS8615856B1Apparatus and method for forming self-retaining sutures

Publication Date: 2013.12.31 ETHICON INC

AI summary

An apparatus and method for forming retainers on a continuous strand such as, for example, of suture material and a suture produced by the same. The apparatus may include a retainer forming member configured to rotate about a first axis. The retainer forming member may include a cutter, the cutting edge of which may directed substantially inward toward, or outward away from, the first axis to define a retainer forming zone when the retainer forming member rotates about the first axis. The apparatus may further include a support member arranged adjacent to the retainer forming member and configured to receive and support the continuous strand in the retainer forming zone. When the retainer forming member rotates about the first axis, the passing strand may be intermittently or continuously cut by the cutting edge of the cutter.