Warp Knit Fabric Self-Fixating Mesh for Hernia Repair
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Solution Overview
Problem
Existing mesh implants for hernia repair and other medical applications often fail due to degradation or mechanical failure, which can lead to hernia recurrence. Current meshes are typically woven and require sutures for fixation, leading to potential unraveling and suture slip issues.
Innovation Solution
A warp knit fabric with a biocompatible implantable mesh of unitary construction, featuring a first knitted portion and a second knitted portion with alternating knitting sequences. The second portion comprises detached strips that run the length of the fabric, minimizing separate strands and eliminating the need for sutures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If woven mesh implants are used for hernia repair, then the mesh can be manufactured with existing weaving technology, but the mesh requires sutures for fixation which can slip and cause unraveling
Solution Approach 1:
The invention extracts and eliminates the suture component from the hernia repair system by integrating fixation functionality directly into the mesh structure through self-fixating loops and bars that engage with tissue without requiring separate sutures
Solution Approach 2:
The invention merges the mesh body and fixation elements into a single integrated unitary construction where the mesh strands continuously form both the mesh structure and the self-fixating loops, eliminating the need for separate suture materials
2Strength
If mesh implants are used to reinforce tissue, then the mesh can close the hernia defect, but the mesh may degrade or fail mechanically leading to hernia recurrence
Solution Approach 1:
The invention changes the structural parameters of the mesh by using a specific knit pattern with controlled loop formations and strand configurations that optimize both initial strength and long-term durability while allowing tissue integration
Solution Approach 2:
The invention uses composite construction combining different strand configurations within the same knit structure, including load-bearing strands and flexible integration strands, to achieve optimal balance between strength and tissue compatibility
3Ease of operation
If sutures are used to fixate the mesh, then the mesh can be secured to surrounding tissue, but the sutures can slip causing mesh displacement and surgical failure
Solution Approach 1:
The invention implements self-service fixation where the mesh structure automatically forms engagement loops and bars that secure to tissue without requiring external suture materials or additional fixation components
4Ease of manufacture
If the mesh is constructed with multiple separate strands, then the mesh can be assembled from discrete components, but the junctures between strands can fail and cause unraveling
Solution Approach 1:
The invention merges all separate strand components into a single continuous knitted structure where strands are interconnected through knit loops rather than separate junctions, eliminating weak points at strand junctures
Solution Approach 2:
The invention inverts the conventional approach by instead of joining separate strands at junctions, the structure is formed as a continuous knit where each strand is looped through others, making the entire structure inherently interconnected without discrete join points
Data Source
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AI summary
A warp knitted fabric formed by a warp knitting machine includes a first knitted portion formed using a first knitting sequence in a machine direction, the first knitted portion comprises at least two strips extending in the machine direction, the at least two strips being detached from one another along their lengthwise edges. The second knitted portion has the same width as the first knitted portion, and the first knitted portion and the second knitted portion alternate sequentially in the machine direction and are formed of a single set of continuous textile strands.