Surgical Mesh Pore Stabilization Without Cutting Fibers
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Solution Overview
Problem
Surgical mesh used for pelvic floor or abdominal wall reinforcement faces a challenge in balancing pore size for cell ingrowth and tensile strength, and existing methods of creating holes for attachment compromise the mesh's integrity and strength.
Innovation Solution
A method to create dimensionally stabilized pores in surgical mesh fabric using a pin frame assembly and peg plate system, where the mesh is annealed with tapers to permanently shape and enlarge targeted pores without cutting the fibers, maintaining the mesh's strength and integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If pore size is increased to encourage cell in-growth, then cell integration is improved, but tensile strength is compromised
Solution Approach 1:
The patent applies preliminary action by heat-setting the mesh fabric before implantation to pre-stabilize the pore dimensions. The fabric is heat-treated at temperatures between 60-150°C to permanently set the pore size, ensuring that the pores maintain their enlarged dimensions for cell in-growth while the surrounding fabric structure retains its tensile strength without requiring post-implantation adjustment
2Ease of operation
If holes are created by cutting or punching for attachment, then device attachment is enabled, but mesh strength and integrity are compromised
Solution Approach 1:
The patent applies preliminary action by pre-forming attachment holes in the mesh fabric before implantation through a controlled heat-setting process. The holes are created by locally heating and relaxing the fabric structure, which permanently sets the pore shape and size without cutting or mechanically punching the fibers. This preliminary formation of attachment sites enables subsequent device attachment while preserving the continuous fiber structure and overall mesh integrity
Solution Approach 2:
The patent replaces mechanical cutting or punching systems with a thermal field system to create attachment holes. Instead of using blades or punches that mechanically sever fibers, the invention uses controlled localized heating to thermally relax and reshape the fabric structure, creating clean, precise holes without fiber damage. This substitution of mechanical action with thermal action eliminates the harmful effects of fiber cutting while achieving the same functional result
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 effectively maintains the tensile strength of the surgical mesh while allowing for larger pores for cell ingrowth and attachment, reducing the risk of fiber irritation and dislodgment, as demonstrated by burst strength tests showing comparable strength to mesh without holes and higher strength than mesh with cut holes.
Implementation Method 1
the mesh is annealed with tapers to permanently shape and enlarge targeted pores without cutting the fibers
Data Source
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Figure 3A~3C
AI summary
A system, method and fabric having a dimensionally stabilized pore. The system has a mesh fabric having a pore, such pore having a first pore perimeter. The system has a support having a support outer perimeter. The support is received into the pore so that the pore perimeter is in contact with the outer support perimeter. When the fabric is thermoset, the pore permanently assumes the shape of the outer support perimeter.