Suture Termination Feature via Ultrasonic Welding
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Solution Overview
Problem
Existing methods for producing self-retaining sutures with anchoring features are costly, inefficient, and often require secondary processing steps such as forming knots or adding secondary components, which can weaken the suture material and increase manufacturing complexity.
Innovation Solution
A method of forming a suture with a termination feature by winding the suture material into a coil 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 traditional methods are used to create anchoring features (knots, clips, or secondary components), then the suture can be anchored in tissue, but the manufacturing cost increases and the suture material strength decreases
Solution Approach 1:
The patent combines the anchoring function directly into the suture material itself by forming a termination feature through welding, eliminating the need for separate anchoring components like knots, clips, or buttons. This merging of functions maintains suture strength while providing reliable anchoring capability.
Solution Approach 2:
The suture material serves its own anchoring needs by forming a termination feature from the suture material itself through welding. This self-service approach eliminates the need for secondary components or additional materials, preserving the integrity and strength of the original suture material.
2Reliability
If knots or secondary components are used for anchoring, then the suture can be secured in tissue, but the manufacturing complexity and number of secondary operations increase
Solution Approach 1:
The patent merges the anchoring feature creation into the main suture manufacturing process through welding, eliminating the need for separate secondary operations to attach knots, clips, or other anchoring components. This reduces manufacturing complexity while maintaining anchoring reliability.
Solution Approach 2:
The patent extracts the anchoring function from separate components and integrates it directly into the suture material through the formation of a termination feature. This eliminates the need for secondary anchoring components and simplifies the manufacturing process.
3Reliability
If thermal welding is used to form the termination feature, then the suture material can be welded into a stable anchor, but the material may be exposed to elevated temperatures that could weaken it
Solution Approach 1:
The patent replaces traditional thermal welding with ultrasonic welding, which uses mechanical vibration energy instead of external heat sources. This substitution allows the formation of a stable anchor while minimizing thermal exposure to the suture material, preserving its strength and integrity.
Solution Approach 2:
The ultrasonic welding process utilizes phase transitions through mechanical vibration, where the high-frequency vibrations generate localized friction and heat only at the welding interface, rather than exposing the entire suture material to elevated temperatures. This enables stable anchor formation with minimal impact on material strength.
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 solution provides a strong, efficient, and cost-effective anchoring mechanism that enhances the suture's stability and strength without exposing the material to elevated temperatures, reducing manufacturing costs and complexity.
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 energy being sufficient to melt at least a portion of the coiled second end
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.