Method for forming a mesh having a barbed suture attached thereto and the mesh thus obtained

• US 10,682,215 B2
• Filed: 09/27/2017
• Issued: 06/16/2020
• Est. Priority Date: 10/21/2016
• Status: Active Grant

• Current Assignee: Sofradim Production
• Original Assignee: Sofradim Production
• Inventors: Couderc, Xavier, Bailly, Pierre
• Primary Examiner(s): Daniels, Matthew J
• Assistant Examiner(s): Swier, Wayne K.
• Application Number:
  US15/716,979
• Publication Number:
  US 20180110605A1
• Time in Patent Office: 993 Days
• CPC Class Codes: A61B 2017/06176 with protrusions, e.g. barbs
• 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 2250/0036 differing in thickness
• CPC Class Codes: D04B 21/12 characterised by thread material
• CPC Class Codes: D10B 2509/04 Sutures
• CPC Class Codes: D10B 2509/08 Hernia repair mesh

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 method for forming a prosthetic mesh having at least one barbed suture attached thereto, said barbed suture comprising an elongate body provided with barbs extending substantially radially out from said elongate body, said method comprising the following steps:

a) producing a knitted structure on a warp knitting machine comprising at least one needle-bed comprising at least three guide bars, a first guide bar B1 a second guide bar B2 and a third guide bar B3, said first guide bar B1 being threaded with first yarns of a biocompatible material, said second guide bar B2 being threaded with second yarns of a biocompatible material, said third guide bar B3 being threaded with third yarns of a biocompatible material, said knitted structure being produced on a determined length along a warp direction corresponding to a total number of N stitches ranging from 1 to N completed along said warp direction by the machine, N being an integer above 7, wherein

i) a first knit portion is produced along stitches ranging from 1 to x, where 1<

x<

N, in which the first, the second and the third guide bars (B1, B2, B3) follow a first knit pattern to produce an openworked knit capable of favoring cellular growth,

ii) a second knit portion is produced for stitches ranging from (x+1) to N, in which the first, the second and the third guide bars (B1, B2, B3) follow a second knit pattern wherein said second and third guide bars B2, B3 produce chain stitches and the first guide bar B1 produces at least a partial weft in which said first yarns complete weft stitches with at least one of said chain stitches, thereby producing at least one weft stitched chain stitch,

b) cutting the second knit portion along the warp direction on both sides of said at least one weft stitched chain stitch and along an edge separating the second knit portion from the first knit portion, so as to remove the second knit portion from the knitted structure while maintaining said weft stitched chain stitch attached to the first knit portion,

wherein the first knit portion forms the mesh and the second or third yarn forming part of said at least one weft stitched chain stitch forms said elongate body of said barbed suture attached thereto, the first yarns cuts extending from said weft stitches of said at least one weft stitched chain stitch forming said barbs of said barbed suture.

2. The method of claim 1, wherein the second knitting pattern followed by the first guide bar B1 during step a)ii) produces at least a partial weft in which said first yarns complete weft stitches with a plurality of chain stitches, thereby producing a plurality of weft stitched chain stitches, and wherein the cutting of step b) is repeated for each weft stitched chain stitch, thereby producing a plurality of barbed sutures attached to the first knit portion.

3. The method of claim 1, wherein said elongate body of said barbed suture is formed of second yarns only.

4. The method of claim 1, wherein the warp knitting machine comprises two needle-beds, a first needle-bed comprising said first, second and third guide bars (B1, B2, B3), and a second needle-bed comprising fourth guide bar B4, fifth guide bar B5 and sixth guide bar B6, said fourth guide bar B4 being threaded with fourth yarns of a biocompatible material, said fifth guide bar B5 being threaded with fifth yarns of a biocompatible material, said sixth guide bar B6 being threaded with sixth yarns of a biocompatible material,

wherein step a) comprises a step 0) occurring before step a)i) as follows:

0) a connecting knit portion is produced along stitches ranging from 1 to y, where 1<

y<

x<

N, in which first, second, third, fourth, fifth and sixth guide bars (B1, B2, B3, B4, B5, B6) produce a three-dimensional openworked knit capable of favoring cellular growth, said knit having a first face produced on said first needle-bed by said first, second and third yarns from said first, second and third guide bars (B1, B2, B3), and a second face, produced on said second needle-bed by said fourth, fifth and sixth yarns from said fourth, fifth and sixth guide bars (B4, B5, B6), said first and second faces being linked together by some of the second, third, fourth and/or fifth yarns, thereby forming linking yarns,

and, in step i), the first knit portion is produced along stitches ranging from (y+1) to x, in which the first, second and third guide bars (B1, B2, B3) produce on the first needle-bed a first bidimensional openworked knit capable of favoring cellular growth, and in which the fourth, fifth and sixth guide bars (B4, B5, B6) produce on the second needle-bed a second bidimensional openworked knit capable of favoring cellular growth,

said first and second bidimensional openworked knits being independent from each other,

and, in step ii) the second knit portion is produced for stitches ranging from (x+1) to N, in which;

on said first needle-bed, a first needle-bed second knit portion is produced, in which said second and third guide bars (B2, B3) produces chain stitches and the first guide bar B1 produces at least a partial weft in which said first yarns complete weft 5 stitches with at least one of said chain stitches, thereby producing at least one first weft stitched chain stitch,

on said second needle-bed, a second needle-bed second knit portion is produced, in which said fourth and fifth guide bars (B4, B5) produces chain stitches and the sixth guide bar B6 produces at least a partial weft in which said sixth yarns complete weft stitches with at least one of said chain stitches, thereby producing at least one second weft stitched chain stitch,

said first needle-bed second knit portion and said second needle-bed second knit portion being independent from each other

wherein step b) comprises;

cutting the first needle-bed second knit portion along the warp direction on both sides of said at least one first weft stitched chain stitch and along an edge separating the first needle-bed second knit portion from the first bidimensional openworked knit, so as to remove the first needle-bed second knit portion from the knitted structure while maintaining said at least one first weft stitched chain stitch attached to the first bidimensional openworked knit,

cutting the second needle-bed second knit portion along the warp direction on both sides of said at least one second weft stitched chain stitch and along an edge separating the second needle-bed second knit portion from the second bidimensional openworked knit, so as to remove the second needle-bed second knit portion from the knitted structure while maintaining said at least one second weft stitched chain stitch attached to the second bidimensional openworked knit,

wherein the method further comprises the following steps occurring after step bº

);

cº

optionally cutting said linking yarns from the three-dimensional openworked knit obtained in step a)0) along stitches ranging from 2 to y, and

dº

) opening the knitted structure 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,

wherein the first bidimensional openworked knit, the connecting knit portion, optionally cut according to step cº

), and the second bidimensional openworked knit form altogether the mesh;

the second or third yarn forming part of said at least one first weft stitched chain stitch forms the elongate body of a first barbed suture attached to the first bidimensional openworked knit, the first yarns cuts extending from said weft stitches of said at least one first weft stitched chain stitch forming said barbs of said first barbed suture;

the fourth or fifth yarn forming part of said at least one second weft stitched chain stitch forms the elongate body of a second barbed suture attached to the second bidimensional openworked knit, the sixth yarns cuts extending from said weft stitches of said at least one second weft stitched chain stitch forming said barbs of said second barbed suture.

5. The method of claim 4, wherein the first guide bar B1 on the first needle-bed, respectively by the sixth guide bar B6 on the second needle-bed, during step a)ii), produces at least a partial weft in which said first yarns, respectively said sixth yarns, complete weft stitches with a plurality of chain stitches, thereby producing a plurality of first and second weft stitched chain stitches, and wherein the cutting of step b) is repeated for each of said first and second weft stitched chain stitches, thereby producing a plurality of first barbed sutures attached to the first bidimensional openworked knit, respectively a plurality of second barbed sutures attached to the second bidimensional openworked knit.

6. The method of claim 4, wherein said elongate body of said second barbed suture is formed of fifth yarns only.

7. The method of claim 1, wherein the first yarns are monofilaments.

8. The method of claim 1, wherein the sixth yarns are monofilaments.

9. The method of claim 1, further comprising a stretching step during which the second knit portion produced in step a)ii) and/or the attached barbed suture obtained in step bº

) is submitted to a stretching treatment.

10. The method of claim 1, wherein the attached barbed suture is submitted to a twisting treatment.

11. The method of claim 1, further comprising a heat-setting step during which either the second knit portion produced in step a)ii) or the attached barbed suture resulting from step b) is submitted to a heat-setting treatment.

12. A prosthetic mesh having at least one barbed suture attached thereto, said barbed suture comprising an elongate body made of a yarn of biocompatible material, provided with barbs extending substantially radially out from said elongate body, said barbs being yarns cuts made of a biocompatible material, where said yarns cuts are stitched to said yarn forming said elongate body, said prosthetic mesh being obtained by the method according to claim 1.

13. The method of claim 4, wherein said first and second faces are linked together the third and/or fourth yarns crossing from the first needle-bed to the second needle-bed.