Self-Retaining Suture Calibration via Optical Blade Positioning
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Solution Overview
Problem
Existing devices for forming self-retaining sutures face challenges with blade wear, thermal warping, and misalignment, leading to inconsistent cut quality and tensile strength over time, especially after blade changes.
Innovation Solution
A non-contact laser calibration method that measures the blade edge position by emitting light through a hole in the blade housing and receiving it on the other side, providing a calibration value to adjust the blade position and ensure precise cutting, combined with a rotatable blade holder and anvil system for accurate retainer formation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a blade is used to cut retainers in a suture, then self-retaining sutures can be formed, but the blade becomes dull, warped, or misaligned over time leading to inconsistent cut quality
Solution Approach 1:
The patent replaces mechanical blade positioning and alignment methods with an optical measurement system. A laser emitter projects a beam through a measurement axis hole in the blade holder, and a sensor detects the beam position to determine blade edge location. This optical substitution eliminates mechanical wear and alignment drift, providing consistent measurement over extended periods without blade changes.
Solution Approach 2:
The patent implements a feedback mechanism where the optical measurement system continuously monitors blade edge position and provides data that can be used to adjust or compensate for blade wear and misalignment. The system measures the actual blade position and compares it to the desired position, enabling real-time or periodic corrections to maintain cut quality consistency throughout the blade's service life.
2Manufacturing precision
If the blade position is manually adjusted, then cutting accuracy can be improved, but user error and positioning inconsistency increase
Solution Approach 1:
The patent replaces manual mechanical positioning with an automated optical measurement and control system. The laser-based measurement system objectively determines blade edge position without human intervention, eliminating user error and positioning inconsistency. The system provides precise numerical data about blade position that can be automatically used for adjustment, reducing operational complexity despite the added measurement capability.
Solution Approach 2:
The patent enables the system to self-measure and self-adjust blade position without requiring user expertise or manual intervention. The optical measurement system automatically detects blade edge location and provides feedback that can trigger automated compensation mechanisms, allowing the system to maintain precision independently of operator skill level.
3Stability of the object's composition
If the blade is held securely in place, then blade stability is improved, but the blade position may still shift over use
Solution Approach 1:
The patent implements continuous feedback monitoring of blade position using the optical measurement system. Even when the blade is securely held, the system periodically measures the blade edge position through the measurement axis hole and detects any shifts or warping. This feedback enables real-time compensation or alerting, maintaining cutting consistency despite physical constraints on blade movement.
Solution Approach 2:
The patent supplements mechanical blade securing with an optical monitoring system that detects position changes without physical contact. The laser measurement system can detect blade warping, shifting, or wear-induced position changes that mechanical securing alone cannot prevent, providing an additional layer of reliability for maintaining cutting consistency.
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 maintains consistent tensile strength and retainer formation quality over multiple cutting cycles, minimizing user error and blade position changes, ensuring precise and secure suture retention.
Implementation Method 1
emitting light along the measurement axis from the light emitting device, through the hole, and received by the light receiving device; and measuring the amount of light received by the light receiving device and providing a calibration value based upon the amount of light received
Data Source
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AI summary
An apparatus and method for improved cutting of self-retaining elements on a suture material, including the use of an improved calibration system. The calibration system includes a light emitting source and light receiving source, emitting light through a blade housing where the blade edge is within the light emitted pathway. The blade housing can be moved in accordance with the calibration information.