Medical Suture Micro Cogs Thermal Forming
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Solution Overview
Problem
Existing medical sutures face limitations in size and strength due to cutting methods, leading to tissue damage, reduced anchoring ability, and rapid bio-absorption, which results in tissue disintegration and loss of anchoring function.
Innovation Solution
A medical suture with micro cogs formed on its surface through a heating and pressing method that maintains molecular orientation and tensile strength, allowing for adjustable cog size and shape, and anchoring in the opposite direction of insertion, using an overflow mould and controlled temperature and pressure to prevent burr formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Shape
If the cutting method is used to form barbs on the suture surface, then the barb formation is achieved, but the tensile strength of the suture is greatly decreased
Solution Approach 1:
The invention changes the manufacturing parameters from mechanical cutting to thermal processing. By controlling temperature and pressure parameters during heating and pressing, micro cogs are formed without cutting the suture fibers, thereby maintaining tensile strength while achieving the desired surface morphology for tissue anchoring.
Solution Approach 2:
The invention replaces the mechanical cutting system with a thermal-field system. Instead of using blades or cutting tools that mechanically remove material and damage fibers, the invention uses controlled heating and pressing to reshape the suture surface into micro cogs, substituting mechanical action with thermal and pressure fields.
2Shape
If the cutting method is used to form barbs, then the barb structure is created, but the suture strength is greatly decreased due to damage to the spun thread
Solution Approach 1:
The invention changes the manufacturing parameters from mechanical cutting to thermal processing. By controlling temperature and pressure parameters during heating and pressing, micro cogs are formed without cutting the suture fibers, thereby maintaining tensile strength while achieving the desired surface morphology for tissue anchoring.
3Reliability
If barbs are formed by cutting the suture surface, then the anchoring function is achieved, but the distal end of the barb becomes too sharp causing stimulus to tissues or nerves
Solution Approach 1:
The thermal processing parameters (temperature, pressure, duration) control the morphology of the micro cogs to have rounded tips rather than sharp edges. This eliminates tissue irritation while preserving the anchoring function through the cog structure's mechanical interlocking capability.
4Shape
If the cutting method is used to form slender barbs, then the barb formation is achieved, but the barbs are rapidly bio-absorbed causing loss of tissue anchoring ability
Solution Approach 1:
The thermal processing parameters (temperature, pressure, duration) control the morphology and density of the micro cogs to have rounded tips rather than sharp edges. This eliminates tissue irritation while preserving the anchoring function through the cog structure's mechanical interlocking capability.
5Reliability
If knots are formed in the suture to achieve tissue anchoring, then the anchoring function is achieved, but excessive folding and curving occur causing strength decrease at the knots
Solution Approach 1:
The invention extracts the anchoring function from the knot structure and relocates it to the suture surface micro cogs. By forming micro cogs directly on the suture surface through heating and pressing, the anchoring capability is separated from the continuous suture body, eliminating stress concentration and folding at knot locations while maintaining overall suture strength.
6Reliability
If conventional methods are used to form tissue anchoring structures, then the anchoring function is achieved, but the structures are larger and harder causing great pains to patients
Solution Approach 1:
The invention segments the anchoring function into multiple fine micro cogs distributed along the suture surface, rather than using a single large anchoring structure. This segmentation creates numerous small contact points that are softer and more compliant, reducing patient discomfort while collectively providing sufficient anchoring force.
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 suture achieves 80-90% of the tensile strength of a spun thread, delays tissue anchoring force weakening, and maintains anchoring ability for extended periods, suitable for surgical applications like facelifts without physical knots or excessive tissue damage.
Implementation Method 1
A medical suture with micro cogs formed on its surface through a heating and pressing method
Implementation Method 2
using an overflow mould and controlled temperature and pressure to prevent burr formation
Data Source
Figure 1(a)~2(c)
Figure 3~4(b)
AI summary
Provided are a medical suture having micro cogs on a surface thereof and a method of manufacturing the medical suture. The method of manufacturing a medical suture includes steps of: producing a suture preform where micro cogs are formed on a surface thereof by heating and pressing a raw material of a suture for surgery in an overflow mould in a heat-press solid-phase forming method; and producing a suture with twist maintained by applying a tensile force and a rotational force to the suture preform in a vacuum state where a specific temperature condition is maintained.