Medical Sling Overmolding for Smooth Transition and Strength
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Solution Overview
Problem
Existing single incision slings for stress incontinence patients face issues with reduced strength, higher tissue erosion, and abrupt profile changes during implantation due to the need to reduce mesh size at anchor interfaces, leading to tissue trauma.
Innovation Solution
A method of overmolding larger sling mesh widths within smaller polymeric anchors without trimming the mesh, using a thermosetting process to maintain strength and create a smooth transition, minimizing tissue trauma and maximizing bond strength between the mesh and anchors.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the mesh size is reduced at the anchor interfaces to fit within smaller anchors, then the sling can be retained in the body, but the strength of the sling assembly is reduced
Solution Approach 1:
The patent embeds the mesh ends within the anchor structure through overmolding, where the mesh is nested inside the anchor body. This allows the full-strength mesh to be retained while fitting within the confined space of the anchor, eliminating the need to reduce mesh size and thereby maintaining sling assembly strength.
Solution Approach 2:
The patent combines the mesh and anchor into a single integrated structure through overmolding. The mesh ends are molded directly into the anchor, creating a unified assembly where the full-strength mesh and anchor work together as one component, eliminating the need to compromise mesh strength for fitment.
2Ease of manufacture
If the mesh size is reduced at the anchor interfaces, then the sling can be implanted, but tissue erosion increases during implantation
Solution Approach 1:
The mesh ends are nested within the anchor body through overmolding, creating a streamlined profile that fits within the anchor without requiring size reduction. This eliminates abrupt transitions and sharp edges that could cause tissue erosion during implantation, while maintaining full mesh strength and implantability.
3Reliability
If the mesh size is reduced at the anchor interfaces, then the sling can be retained, but abrupt profile changes occur causing tissue trauma
Solution Approach 1:
The mesh ends are nested within the anchor structure, creating a smooth, continuous profile without abrupt transitions. This eliminates sharp edges and sudden changes in diameter that could cause tissue trauma during implantation, while maintaining the retention function through the overmolded anchor-mesh integration.
Solution Approach 2:
The patent applies different properties to different parts of the assembly: the mesh maintains its full strength and flexibility in the body, while the anchor provides structural support and retention at the ends. The overmolding process creates a smooth transition zone that combines these properties without abrupt changes, reducing tissue trauma.
4Reliability
If the anchors are increased in size to accommodate the mesh, then the mesh can be retained, but the device complexity increases
Solution Approach 1:
The mesh ends are nested within the existing anchor dimensions through overmolding, eliminating the need to increase anchor size. This maintains a compact, minimally invasive device profile while ensuring secure mesh retention through the integrated overmolded structure.
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 solution maintains sling strength, reduces tissue erosion, and minimizes trauma during implantation by securing both ends of the sling within smaller anchors, ensuring a smooth transition and maximizing bond strength.
Implementation Method 1
the end or ends are thermoset such that the end or ends maintains the smaller width when unconstrained
Data Source
AI summary
A medical sling for supporting an anatomical feature having ends that are tapered using a folding fixture and then thermoset. The thermoset ends hold the bunched or folded shape thus allowing the ends to be removed from the fixture and placed into a mold assembly where anchors are molded over the ends.