Single-Step Warp Knit Base for H-Shaped Hernia Prostheses

The patent merges the production of underlay layer, onlay layer, and connector into a single integrated knitting process. The warp knitting machine simultaneously produces all three components in one continuous operation, eliminating the need for separate production and joining steps. This resolves the contradiction by maintaining manufacturing flexibility through integrated production while dramatically reducing production time and process complexity.

The invention combines multiple production operations into a single knitting process using a warp knitting machine with multiple guide bars. The machine produces underlay layer, onlay layer, and connector as an integrated structure in one operation, eliminating the complexity of separate production and joining steps while maintaining the adaptability to produce different prosthesis configurations.

The invention extracts the joining operation entirely from the production process. Instead of using thermal welding or sewing to join separate components, the warp knitting machine creates an integrated structure where the underlay layer, onlay layer, and connector are formed as a single continuous knitted piece. This eliminates areas of weakness and rigidity that would otherwise be created by joining operations, while maintaining the necessary structural integrity through the continuous knitted construction.

The invention creates a dynamic structure through the knitted construction, where the connector portion allows controlled movement and orientation adjustment. The interlocking loops of the knitted material provide structural stability while inherently allowing flexibility and mobility. This enables the prosthesis to be easily oriented and adapted during surgery while maintaining structural integrity, resolving the contradiction between rigidity and mobility.