Barbed prosthetic knit and hernia repair mesh made therefrom as well as process for making said prosthetic knit

• US 10,342,652 B2
• Filed: 09/12/2016
• Issued: 07/09/2019
• Est. Priority Date: 12/29/2011
• Status: Active Grant

• Current Assignee: Sofradim Production
• Original Assignee: Sofradim Production
• Inventors: Lecuivre, Julie, Bourges, Xavier, Bailly, Pierre
• Primary Examiner(s): Woo, Julian W
• Application Number:
  US15/262,165
• Publication Number:
  US 20160374792A1
• Time in Patent Office: 1,030 Days
• CPC Class Codes: A61F 2/0063 Implantable repair or support meshes, e.g. hernia meshes
• CPC Class Codes: A61F 2002/0068 having a special mesh pattern
• CPC Class Codes: A61F 2220/0016 with sharp anchoring protrusions, e.g. barbs, pins, spikes
• CPC Class Codes: A61F 2240/001 Designing or manufacturing processes
• CPC Class Codes: D04B 21/12 characterised by thread material
• CPC Class Codes: D04B 21/14 Fabrics characterised by the incorporation by knitting, in one or more thread, fleece, or fabric layers, of reinforcing, binding, or decorative threads; Fabrics incorporating small auxiliary elements, e.g. for decorative purposes pile fabrics D04B21/02; non-woven fabrics in general D04H
• CPC Class Codes: D04B 21/20 specially adapted for knitting articles of particular configuration
• CPC Class Codes: D06C 7/00 Heating or cooling textile fabrics
• CPC Class Codes: D10B 2401/041 thermoplastic; thermosetting
• CPC Class Codes: D10B 2403/0111 One hairy surface, e.g. napped or raised for pile fabrics D03D27/00, D04B1/02, D04B21/02
• CPC Class Codes: D10B 2501/0632 of the touch-and-close type
• CPC Class Codes: D10B 2509/08 Hernia repair mesh

Abstract

The present invention relates to a prosthetic knit based on at least a first yarn of biocompatible polymer material defining first and second opposite and openwork faces, and on at least a second biocompatible and heat-fusible monofilament yarn, forming barbs that protrude outwards from at least said first face and are obtained by melting loops generated by said second yarn, the chart followed for the knitting of said first and second yarns on a warp knitting machine having three guide bars B1, B2, B3 being the following, according to the ISO 11676 standard:—Bar B1: 1.0/0.1//—Bar B2: 1.0/7.7/6.6/7.7//—Bar B3: 2.1/5.5/3.4/0.0// said second yarn following the chart of bar B3. The present invention also relates to a process for manufacturing such a knit.

Claims

1. A prosthetic knit comprising at least a first monofilament yarn of biocompatible polymer material defining first and second opposite faces, at least the second face including openings, and at least a second biocompatible and heat-fusible monofilament yarn which forms barbs that protrude outward from at least said first face, wherein the openings and the barbs are distributed such that when the knit is rolled upon itself at least some of the barbs present on the first face are caused to be trapped within some of the openings on the second face, and when the knit is unrolled the trapped barbs will be released from the openings of the second face by applying an average force of 1.13±

0.33 N.

2. The prosthetic knit according to claim 1, wherein a maximum force of 3.54±

0.85 N can be applied to unroll the knit.

3. The prosthetic knit according to claim 1, wherein the openings and the barbs are distributed such that the knit experiences a number of points of resistance of 52±

11 when the knit is unrolled at a constant extension rate.

4. The prosthetic knit according to claim 1, wherein the first monofilament yarns are made of polyester terephthalate (PET) having a diameter of 0.09 mm.

5. The prosthetic knit according to claim 4, wherein the second heat-fusible monofilament yarn comprises a material selected from polypropylene, polyglycolic acid, polylactic acid, and mixtures thereof.

6. The prosthetic knit according to claim 4, wherein the second heat-fusible monofilament yarn is a polylactic acid monofilament yarn having a diameter of 0.15 mm.

7. The prosthetic knit according to claim 4, wherein the second heat-fusible monofilament yarn is a polypropylene monofilament yarn having a diameter of 0.15 mm.

8. The prosthetic knit according to claim 1, wherein the barbs are not damaged after unrolling.

9. The prosthetic knit according to claim 1, wherein the first yarn is knit on a warp knitting machine having at least three guide bars B1, B2, B3, according to ISO 11676 standard and the first yarn following the chart of bars B1 and B2:

Bar B1;

1.0/0.1//

Bar B2;

1.0/7.7/6.6/7.7//.

10. The prosthetic knit according to claim 1, wherein the second yarn is knit on a warp knitting machine having at least three guide bars B1, B2, B3, according to ISO 11676 standard and the second yarn following the chart of bar B3:

Bar B3;

2.1/5.5/3.4/0.0//.

11. The prosthetic knit according to claim 1, further comprising a non-stick coating made of a biocompatible material.

12. The prosthetic knit according to claim 1, wherein the first face includes openings.

13. A method for hernia repair comprising

rolling a prosthetic knit up on itself, the knit including at least a first yarn of biocompatible polymer material defining first and second opposite and openwork faces, and at least a second biocompatible and heat-fusible monofilament yarn which forms barbs that protrude outward from at least said first face and are obtained by melting loops generated by the second yarn, said first and second yarns being knit on a warp knitting machine have three guide bars B1, B2, B3, according to ISO 11676 standard and the following chart

Bar B1:

1.0/0.1//

Bar B2;

1.0/7.7/6.6/7.7//

Bar B3;

2.1/5.5/3.4/0.0//

the second yarn following the chart of bar B3,

conveying the rolled knit to a site of implantation, and

unrolling the knit by exerting a minimal force to disentangle the barbs the minimal force being an average of 1.13±

0.33 N.

14. The method of claim 13, further comprising introducing the rolled knit into a trocar prior to conveying the rolled knit to the site of implantation.

15. The method of claim 13, wherein the first monofilament yarns are made of polyester terephthalate (PET) having a diameter of 0.09 mm.

16. The method of claim 13, wherein the second heat-fusible monofilament yarn comprises a material selected from polypropylene, polyglycolic acid, polylactic acid, and mixtures thereof.

17. The method of claim 16, wherein the second heat-fusible monofilament yarn is a polylactic acid monofilament yarn having a diameter of 0.15 mm.

18. The method of claim 16, wherein the second heat-fusible monofilament yarn is a polypropylene monofilament yarn having a diameter of 0.15 mm.

19. The method of claim 13, wherein the barbs are not damaged after unrolling.

20. The method of claim 14, wherein the yarns comprise an intrinsic stiffness that naturally returns the rolled knit to a flat configuration upon removal from the trocar.