Suture Termination Feature via Coiled End Welding
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Solution Overview
Problem
Existing methods for producing self-retaining sutures with anchoring features at the non-needled end are costly and require complex secondary operations, often involving the formation of knots or addition of secondary components, which can weaken the suture and increase manufacturing costs.
Innovation Solution
A method and apparatus for forming a suture with a termination feature at the non-needled end by winding the suture around a pin and applying energy to weld it into a stable anchor, eliminating the need for knots or additional components, and allowing for continuous in-line processing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If knots or secondary components are used to create anchoring features at the non-needled end of self-retaining sutures, then the suture can be anchored in tissue, but the manufacturing cost increases and the suture strength decreases
Solution Approach 1:
The invention extracts the anchoring function from separate secondary components (knots, clips, anchors) and integrates it directly into the suture fiber itself through radial flutes formed on the suture surface. This eliminates the need for additional anchoring components while maintaining the anchoring capability, thereby preserving suture strength and reducing manufacturing complexity.
Solution Approach 2:
The invention applies local quality by creating radial flutes only at specific locations on the suture (particularly at the non-needled end) where anchoring is needed, rather than modifying the entire suture. The flutes are formed by localized contact with a forming surface during manufacturing, providing anchoring features precisely where required without affecting the overall suture integrity.
2Reliability
If knots or secondary components are used to create anchoring features, then the suture can be anchored in tissue, but the manufacturing process becomes more complex and costly
Solution Approach 1:
The invention merges the anchoring feature formation with the primary suture manufacturing process. The radial flutes are formed during the extrusion or drawing process by contacting the suture with a forming surface, combining what would otherwise be separate operations (suture production and anchoring feature addition) into a single integrated process, thereby simplifying manufacturing and reducing costs.
Solution Approach 2:
The suture fiber itself serves the dual function of providing both the structural element and the anchoring mechanism. The radial flutes are formed directly on the suture material during manufacturing, allowing the suture to be self-sufficient without requiring separate anchoring components or secondary assembly operations.
3Reliability
If thermal energy is applied to weld the suture into an anchor, then a stable termination feature is formed, but thermal exposure may weaken the suture material
Solution Approach 1:
The invention applies partial action by using controlled thermal energy only at the specific location where the anchor is formed (the non-needled end of the suture), rather than exposing the entire suture to heat. The thermal welding is localized to create the anchor feature while minimizing thermal exposure to the rest of the suture, thereby maintaining overall suture strength while achieving anchor stability.
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
This approach results in a strong, cost-effective anchor that simplifies the manufacturing process, reduces thermal exposure, and avoids the formation of knots, providing improved strength and stability without the need for additional materials or complex processing steps.
Implementation Method 1
subjecting the coiled second end to application of energy, the energy being sufficient to melt at least a portion of the coiled second end and form a solid unitary termination feature
Implementation Method 2
the application of energy, radio frequency, heat, or ultrasonic energy
Data Source
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AI summary
Polymeric fibers, and apparatuses for and methods of processing such fibers to be useful as sutures, where at least one end of a fiber includes a termination feature. The termination feature is formed through the application of energy to a coiled region of the fiber.