Surgical Suture Offset Tip Manufacturing via Compression Reshaping

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Solution Overview

Problem

Existing surgical needle-suture combinations often result in holes larger than the suture diameter when passed through tissue, leading to issues like blood oozing and infection risks, due to the need for larger needle sizes and techniques that compromise suture flexibility and strength.

Innovation Solution

A method involving the compression and reshaping of a suture's center region to form a core mass and deformed mass, with the deformed mass being cut off and the core reshaped to create a reformed tip with a reduced cross-sectional area, allowing for a more precise and consistent attachment to the needle, maintaining flexibility and strength.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Manufacturing precision

If conventional needle designs with eyes are used to attach sutures, then suture attachment is achieved, but the needle cross-sectional area becomes large resulting in holes larger than the suture diameter

Engineering Contradiction:

Improvehole size matching suture diameterVSAvoidneedle structure complexity

Core Design Contradiction:

Manufacturing precisionVSDevice complexity

Solution Approach 1:

The invention removes the traditional eye structure from the needle and extracts the suture attachment function to a separate distal tip component. The suture is attached to the distal tip which then inserts into a bore hole in the needle, separating the attachment mechanism from the needle body and enabling precise hole sizing.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The suture is divided into distinct functional segments: a distal tip portion for attachment to the needle, a body portion for tissue approximation, and the needle itself. This segmentation allows each component to be optimized independently, with the distal tip having a reduced cross-sectional area for precise needle insertion while the suture body maintains its original diameter for effective tissue closure.

Inventive Principle:

Principle #1Segmentation

2Manufacturing precision

If suture diameter is reduced to match needle hole size, then hole filling is improved, but suture strength and flexibility are compromised

Engineering Contradiction:

Improvesuture diameter consistencyVSAvoidsuture tensile strength

Core Design Contradiction:

Manufacturing precisionVSStrength

Solution Approach 1:

The suture is designed with non-uniform cross-sectional properties: the distal tip has a reduced cross-sectional area optimized for needle insertion and attachment, while the suture body maintains a larger diameter for strength and flexibility. This local differentiation allows each region to fulfill its specific function without compromising overall performance.

Inventive Principle:

Principle #3Local quality

3Strength

If mechanical swaging or melt fusion techniques are used to attach suture to needle, then attachment strength is improved, but suture flexibility and material properties are degraded

Engineering Contradiction:

Improvesuture-needle attachment strengthVSAvoidsuture material properties

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The suture distal tip is pre-formed with a reduced cross-sectional area and specific geometry before attachment to the needle. This preliminary shaping allows the tip to be inserted into the needle bore hole and secured with minimal deformation, preserving the suture's material properties and flexibility while achieving secure attachment.

Inventive Principle:

Principle #10Preliminary action

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 ensures that the hole created by the needle is substantially filled by the suture, reducing blood oozing and infection risks while maintaining the suture's material properties and attachment strength.

Implementation Method 1

compressing a center region of the elongated fiber that is located between the first and second ends thereof for reshaping the center region into a core mass and a deformed mass

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

heating the elongated fiber

Methodology Applied

Scientific EffectHeating: Heating

Data Source

PatentUS11832812B2Systems, devices and methods of making surgical sutures having reformed, reduced diameter, offset tips

Publication Date: 2023.12.05 ETHICON INC

AI summary

A system for making a surgical suture having a reformed tip includes a receiver die having a top surface, a bottom surface, and an elongated channel formed in the top surface that extends between first and second ends of said receiver die. The elongated channel includes a suture channel having a first end and a second end, a first sloping surface that extends downwardly between the first end of the suture channel and the first end of the receiver die, and a second sloping surface that extends downwardly between the second end of the suture channel and the second end of the receiver die. The system includes an upper die having a top surface and a bottom surface that opposes the top surface of the receiver die. The system has an open die position in which the bottom surface of the upper die is spaced away from the top surface of the receiver die and a closed die position in which the bottom surface of the upper die is in contact with the top surface of the receiver die. A cutting element is coupled with the receiver die and the upper die.