Method for forming a mesh having a barbed suture attached thereto and the mesh thus obtained
11696819 · 2023-07-11
Assignee
Inventors
Cpc classification
A61F2/0063
HUMAN NECESSITIES
A61F2220/0016
HUMAN NECESSITIES
International classification
A61F2/00
HUMAN NECESSITIES
Abstract
The invention relates to a method for forming a mesh having a barbed suture attached thereto, comprising the following steps: a) producing a knitted structure on a knitting machine comprising at least one needle-bed with three guide bars, on a length corresponding to N stitches ranging from 1 to N, wherein i) a first knit portion is produced along stitches ranging from 1 to x, where 1<x<N, ii) a second knit portion is produced for stitches ranging from (x+1) to N, in which the knitting pattern produces at least one weft stitched chain stitch, b) cutting the second knit portion on both sides of the weft stitched chain stitch and along an edge separating the second knit portion from the first knit portion, while maintaining the weft stitched chain stitch attached to the first knit portion. The invention also relates to the mesh obtained by this method.
Claims
1. A prosthesis for hernia repair comprising a mesh including a first knit portion including at least first and second biocompatible yarns, and at least one barbed suture attached to the first knit portion, the barbed suture including an elongate body and a plurality of first yarn cuts extending substantially radially out from the elongate body forming barbs, the elongate body having at least one weft stitched chain stitch made from at least one of the second biocompatible yarn or a third biocompatible yarn, and the first yarn cuts made from the first biocompatible yarns stitched to the at least one second or third biocompatible yarns of the elongate body.
2. The prosthesis of claim 1, wherein the first yarn cuts forming the barbs extend from the weft stitch of the at least one weft stitched chain stitch of the elongate body.
3. The prosthesis of claim 1, wherein the elongate body includes a plurality of weft stitched chain stitches.
4. The prosthesis of claim 1, wherein the at least one weft stitched chain stitch is made from both the second and third biocompatible yarns.
5. The prosthesis of claim 1, wherein the first biocompatible yarn forms the weft stitch of the weft stitched chain stitch, and the second and third biocompatible yarns form the chain stitch of the weft stitched chain stitch.
6. The prosthesis of claim 1, wherein the elongate body of the barbed suture is formed of the second biocompatible yarns only.
7. The prosthesis of claim 1, wherein the first knit portion further includes the third biocompatible yarn.
8. The prosthesis of claim 1, wherein the mesh and the barbed suture are a knitted structure having a determined length in a warp direction corresponding to a total number of N stitches ranging from 1 to N in the warp direction, N being an integer above 7, wherein the total number of N stitches includes a number of stitches for the first knit portion ranging from 1 to x, where 1<x<N and a number of stitches for the elongate body ranging from (x+1) to N.
9. The prosthesis of claim 1, wherein the at least one barbed suture has a final length from about 0% to about 90% greater than an initial knit length of the at least one barbed suture.
10. The prosthesis of claim 1, wherein the at least one barbed suture has a final length of about 40% greater than an initial knit length of the at least one barbed suture.
11. The prosthesis of claim 1, wherein the at least one barbed suture has a final length about 40% greater than an initial knit length of the at least one barbed suture and includes an angle of about 45° between the first yarn cuts and the elongate body.
12. The prosthesis of claim 1, wherein the at least one barbed suture includes one or more medico-surgically useful substances.
13. The prosthesis of claim 1, wherein the at least one barbed suture additionally includes a needle on a free end of the elongate body.
14. The prosthesis of claim 1, wherein the first knit portion includes at least one weft stitched chain stitch.
15. The prosthesis of claim 1, wherein the at least one barbed suture includes active portions including the barbs and passive portions free of the barbs with varying lengths therebetween along the elongate body.
16. The prosthesis of claim 1, wherein the at least one barbed suture is stretched, twisted, heat-set, or combinations thereof.
17. The prosthesis of claim 1, wherein the first knit portion is an openworked knit capable to favoring cellular growth.
Description
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
(1) The advantages of the method of the invention will appear more clearly from the following examples and attached drawings in which:
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DETAILED DESCRIPTION OF THE INVENTION
Examples
Example 1
(14) In the present example, a prosthetic mesh 1 (see
(15) In a first step, step a.sup.o), a knitted structure 2 (see
(16) In other embodiments, the knitted structure could be produced on other lengths corresponding to other number of stitches.
(17) In the present example, all the knitting patterns are given according to the ISO 11676 standard (publication year 2014).
(18) With reference to
(19) In a step a)i), the first knit portion 13 capable of favoring cellular growth is produced for stitches ranging from 1 to 30.
(20) The knitting pattern followed by bars B1, B2 and B3 is the following one: Bar B1: (5.4/3.2/0.1)×10// Bar B2: (5.4/3.2/0.1)×10// Bar B3: (0.1/2.3/5.4)×10//
(21) In a step a)ii), the second knit portion 12 is produced for stitches ranging from 31 to 70.
(22) The knitting pattern followed by bars B1, B2 and B3 is the following one: Bar B1: (0.0/2.3/5.5/3.2)×10// Bar B2: (2.3/2.3/3.2/3.2)×10// Bar B3: (2.3/2.3/3.2/3.2)×10//
(23) In both steps a)i) and aii), B1 is threaded 1 full, 3 empty, B2 is threaded 1 full, 3 empty and B3 is threaded 1 full, 3 empty, along the whole width of the machine.
(24) Such a pattern results in a distance between a weft stitched chain stitch and the two adjacent chain stitches of about 3.5 mm.
(25) The yarns threaded in guide bar B1 (first yarns) are polypropylene monofilaments having a diameter of 0.20 mm.
(26) The yarns threaded in guide bar B2 (second yarns) are multifilament yarns of ultra high molecular weight polyethylene, such as those marketed by the company DSM under the tradename “Dyneema Purity®”. These multifilaments have a tensile strength of 35 cN/dTex.
(27) The yarns threaded in guide bar B3 (third yarns) are polypropylene monofilaments having a diameter of 0.30 mm.
(28) With reference to
(29) With reference to
(30) For sake of clarity, the figures show the cutting step for one weft stitched chain stitch 6 only. Anyway, the cutting step may be repeated for each weft stitched chain stitch 6 present on the width of the knitted structure 2 corresponding to the desired width of the final mesh 1 to be obtained.
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(32) As shown on this Figure, the attached weft stitched chain stitch 6 which is also the elongate body 9 of the attached barbed suture 10 extends along a longitudinal axis A1, and the monofilament cuts 7, which are also the barbs 8, each extend along a longitudinal axis A2. On
(33)
(34) As appears from the cutting step shown on
(35) Although
(36) With reference to
(37) With reference to
(38) The attached barbed suture 10 of
(39) In embodiments not shown, the knitting pattern used in step a)ii) above may result in all chain stitches being also weft stitched chain stitches, when the first yarns produce weft stitches with all chain stitches produced by the second and the third guide bars. In other embodiments, the knitting pattern may produce only one weft stitched chain stitch out of three, four, five, etc. . . . chain stitches present in the second knit portion, which may result in variations of the distance between two adjacent weft stitched chain stitches. Alternatively, this distance may vary due to different threading-in of the guide bars.
(40) The mesh 1 with the barbed suture 10 attached thereto may be particularly useful in hernia repair. The mesh may play its function of abdominal wall repair while the one or more barbed sutures 10 attached thereto may be used by the surgeon in order to fix the mesh to the abdominal wall. The surgeon does not have to look for sutures at the time he needs to fix the mesh to the biological tissue. Moreover, because of the barbed nature of the suture(s) attached to the mesh, the surgeon needs not perform surgical knots. The barbs of the attached barbed suture(s) perform the anchoring function of the suture into the biological tissue very efficiently.
Example 2
(41) In the present example, a prosthetic mesh 28 having a plurality of barbed sutures (10; 10′) attached thereto (see
(42) The Raschel knitting machine comprises a first needle-bed comprising three guide bars B1, B2 and B3 and a second needle-bed comprising three guide bars B4, B5 and B6. In the present example, the same references that are used for the production and steps performed in relation to the first needle-bed will be maintained for the production and steps performed in relation to the first needle-bed, but with a “prime” indicated after the reference digit.
(43) In the present example, all the guide bars (B1, B2, B3, B4, B5, B6) are threaded 1 full, 3 empty along the whole width of the machine and all the knitting patterns are given according to the ISO 11676 standard (publication year 2014).
(44) In the present example:
(45) first guide bar B1 is threaded with first yarns and sixth guide bar B6 is threaded with sixth yarns, the first and sixth yarns being monofilaments of polypropylene having a diameter of about 0.20 mm,
(46) second guide bar B2 is threaded with second yarns, and fifth guide bar B5 is threaded with fifth yarns, the second and fifth yarns being multifilaments of high tenacity polyester having a thickness of 165 dTex,
(47) third guide bar B3 is threaded with third yarns and fourth guide bar B4 is threaded with fourth yarns, the third and fourth yarns being monofilaments of polypropylene having a diameter of about 0.30 mm.
(48) In a first step a), a knitted structure 27 (see
(49) 1.sup.o) During step a)0): for stitches ranging from 1 to 6, a connecting portion 20 is produced under the form of a three-dimensional openworked knit 21 capable of favoring cellular growth, according to the following knitting pattern: B1: (5.4.3.3/3.2.1.1/0.1.3.3)×2// B2: (5.4.3.3/3.2.1.1/0.1.3.3)×2// B3: 0.1.0.1/2.3.2.3/5.4.2.2/0.1.2.2/2.3.4.4/5.4.2.2// B4: 0.1.0.1/2.3.2.3/4.4.5.4/2.2.0.1/2.2.2.3/4.4.5.4// B5: (3.3.5.4/3.3.3.2/1.1.0.1)×2// B6: (3.3.5.4/3.3.3.2/1.1.0.1)×2//
(50) The above knitting pattern allows producing a knit that has a first face produced on the first needle-bed by the first, second and third yarns from the first, second and third guide bars (B1, B2, B3), and a second face, produced on the second needle-bed by the fourth, fifth and sixth yarns from the fourth, fifth and sixth guide bars (B4, B5, B6), the first and second faces being linked together by some of the third and/or fourth, yarns crossing from the first needle-bed to the second needle-bed and vice-versa, thereby forming linking yarns.)
(51) 2.sup.o) During step a)i): for stitches ranging from 7 to 30: a first knit portion 22 is produced. During this step and the subsequent step, independent knits are produced on each of the needle bed in parallel.
(52) On the first needle-bed, a first bidimensional openworked knit 23 capable of favoring cellular growth is produced according to the following knitting pattern:
(53) B1: (5.4.3.3/3.2.1.1/0.1.3.3)×8// B2: (5.4.3.3/3.2.1.1/0.1.3.3)×8// B3: (0.1.2.2/2.3.4.4/5.4.2.2)×8//
(54) On the second needle-bed, a second bidimensional openworked knit 23′ capable of favoring cellular growth is produced according to the following knitting pattern: B4: (2.2.0.1/2.2.2.3/4.4.5.4)×8// B5: (3.3.5.4/3.3.3.2/1.1.0.1)×8// B6: (3.3.5.4/3.3.3.2/1.1.0.1)×8//
(55) The first and second bidimensional openworked knits being independent from each other. They each constitute a bidimensional knit suitable for use as a reinforcement member for the repair of hernia in the abdominal wall.
(56) 3.sup.o) During step a)ii): for stitches ranging from 31 to 70: a second knit portion 24 is produced.
(57) On the first needle-bed, a first needle-bed second knit portion 25 is produced according to the following knitting pattern: B1: (0.0.0.0/2.3.4.4/5.5.5.5/3.2.1.1)×10// B2: (2.3.2.2/2.3.3.3/3.2.3.3/3.2.2.2)×10// B3: (2.3.2.2/2.3.3.3/3.2.3.3/3.2.2.2)×10//
(58) In a similar way as described in Example 1 for the second knit portion 12, in the present example, the knitting pattern followed by the second and third guide bars (B2, B3) produces chain stitches and the knitting pattern followed by the first guide bar B1 produces a partial weft in which said first yarns complete weft stitches with a plurality, four in the example shown in the Figures, of said chain stitches, thereby producing a plurality of weft stitched chain stitches 6, four in the example shown.
(59) On the second needle-bed, a second needle-bed second knit portion 25′ is produced according to the following knitting pattern: B4: (2.2.2.3/2.2.2.3/3.3.3.2/3.3.3.2)×10// B5: (2.2.2.3/2.2.2.3/3.3.3.2/3.3.3.2)×10// B6: 1.1.0.0/0.0.2.3/4.4.5.5/5.5.3.2)×10//
(60) Similarly to what takes place for the first-needle bed, the knitting pattern followed by the fourth and fifth guide bars (B4, B5) produces chain stitches and the knitting pattern followed by the sixth guide bar B6 produces a partial weft in which the sixth yarns complete weft stitches with a plurality, four as shown on the Figures, of said chain stitches, thereby producing a plurality of weft stitched chain stitches, for example four weft stitched chain stitches 6′.
(61) The knitted structure 27 produced in the step a) above is shown on
(62) In a step b.sup.o), with reference to
(63) the first needle-bed second knit portion 25 is cut along the warp direction on both sides of each of the four weft stitched chain stitches 6 obtained by first, second and third guide bars (B1, B2, B3) and along an edge 26 separating the first needle-bed second knit portion 25 from the first bidimensional openworked knit 23, so as to remove the first needle-bed second knit portion 25 from the knitted structure 27 while maintaining the four weft stitched chain stitches 6 attached to the first bidimensional openworked knit 23,
(64) the second needle-bed second knit portion 25′ is cut along the warp direction on both sides of each of the four weft stitched chain stitches 6′ obtained by third, fourth and fifth guide bars (B4, B5, B6) and along an edge 26′ separating the second needle-bed second knit portion 25′ from the second bidimensional openworked knit 23′, so as to remove the second needle-bed second knit portion 25′ from the knitted structure 27 while maintaining the four weft stitched chain stitches 6′ attached to the second bidimensional openworked knit 23′.
(65) The cutting step is performed in the same manner as described in Example 1.
(66) In a step c.sup.o), with reference to
(67) This step may be optional, for example in the case where the connecting knit portion 20 extends already on a length corresponding to 2 stitches only from the start. The purpose of this step c.sup.o) is to reduce the height of the connecting knit portion in the final configuration of the mesh as shown in
(68) If the number of stitches in the warp direction along which the connecting knit portion extends from the start is low enough for not producing any extra thickness in the final configuration of the mesh, than the present step c.sup.o) is unnecessary.
(69) In a step d.sup.o), the knitted structure 27 is opened so as to spread in a single plane the part of the knitted structure obtained from the first needle-bed and the part of the knitted structure obtained from the second needle-bed as shown on
(70) With reference to
(71) In the present example, the elongate bodies 9 of the first barbed sutures 10 are formed of second yarns only and the elongate bodies 9′ of the second barbed sutures 10′ are formed of fifth yarns only.
(72) In other embodiments not shown, the elongate bodies 9 of the first barbed sutures 10 may be formed of third yarns only or of a combination of second and third yarns, and the elongate bodies 9′ of the second barbed sutures 10′ may be formed of fourth yarns only or of a combination of fourth and fifth yarns.
(73) The mesh 28 having barbed sutures (10, 10′) attached thereto as obtained in the present example may be particularly useful in hernia repair. The mesh 28 may play its function of abdominal wall repair while the barbed sutures (10, 10′) attached thereto may be used by the surgeon in order to fix the mesh 28 to the abdominal wall. The surgeon does not have to look for sutures at the time he needs to fix the mesh to the biological tissue. Moreover, because of the barbed nature of the suture(s) (10, 10′) attached to the mesh 28, the surgeon needs not perform surgical knots. As appears from
(74) In addition, the attached barbed sutures (10; 10′) of the mesh 28 may be further submitted to a treatment, such as a stretching treatment, a twisting treatment, a heat-setting treatment and/or a combination of these treatments, so as to provide them with an optimized configuration in function of the intended use of the mesh and sutures, in order to ensure an optimized fixation of the mesh in the biological tissues.
(75) The method of the invention allows preparing prosthetic meshes having one or more barbed suture(s) attached thereto in a very simple way, and in only one single knitting process. The method further allows adapting very easily and in a cost effective manner the nature and structure of the attached barbed suture(s), such as frequency per cm, configuration, spacing, length and surface area of the barbs, depending upon the tissue in which the barbed suture(s) are to be used. With the method of the invention, it is possible to obtain meshes having barbed suture(s) attached thereto, with barbed suture(s) in which the barbs may be arranged in any suitable pattern, for example, helical, linear, or randomly spaced.