TISSUE HOLDING DEVICES AND METHODS FOR MAKING THE SAME

• US 20070257395A1
• Filed: 05/02/2007
• Published: 11/08/2007
• Est. Priority Date: 05/04/2006
• Status: Active Grant

• Current Assignee: Ethicon Incorporated (Johnson & Johnson)
• Original Assignee: Ethicon Incorporated (Johnson & Johnson)
• Inventors: Collier, John, Lindh, David, Nawrocki, Jesse
• Granted Patent: US 7,850,894 B2
• Time in Patent Office: Days
• US Class Current: 264/171.120
• CPC Class Codes: A61B 17/06166 Sutures suture materials A61L17/00; manufacture of artificial threads D01D; treatment of threads D06M
• CPC Class Codes: A61B 2017/00526 Methods of manufacturing
• CPC Class Codes: A61B 2017/00867 shape memory effect for prostheses A61F2210/0014
• CPC Class Codes: A61B 2017/06176 with protrusions, e.g. barbs
• CPC Class Codes: B29C 2043/023 having a plurality of grooves
• CPC Class Codes: B29C 2043/148 using different moulds
• CPC Class Codes: B29C 2043/3615 Forming elements, e.g. mandrels or rams or stampers or pistons or plungers or punching devices
• CPC Class Codes: B29C 43/021 characterised by the shape of the surface
• CPC Class Codes: B29C 43/146 for making multilayered articles
• CPC Class Codes: Y10T 83/4516 Work-feed mechanism in nonfeed motion effects or initiates tool actuation
• CPC Class Codes: Y10T 83/6484 Punch or die station

Abstract

Various methods are provided for forming tissue holding devices having predetermined shapes suitable for use in surgical applications, and devices formed in accordance with such methods are also provided. These methods include press forming methods, and press forming methods in combination with profile punching. Tissue holding devices formed in accordance with such methods include various configurations for a core and a plurality of tissue holding elements extending outwardly from the core.

Claims

1. A method for forming a tissue holding device having a predetermined shape suitable for use in surgical applications, comprising:

providing a first set of dies each having a top surface having a recess therein sized and shaped such that, when the recesses face and are aligned with one another, a first mold cavity is formed therebetween;

providing a polymeric feedstock material;

placing the feedstock material between opposing top surfaces of the first set of dies;

with the feedstock material therebetween, pressing the top surfaces of the first set of dies together until substantially in contact with one another so that the feedstock material deforms to fill the first mold cavity formed therebetween to thereby form a pre-form having a shape of the first mold cavity;

providing a second set of dies each having a top surface having a recess therein sized and shaped such that, when the recesses face and are aligned with one another, a second mold cavity is formed therebetween, the second mold cavity defining the predetermined shape of the tissue holding device;

placing the pre-form between opposing top surfaces of the second set of dies;

with the pre-form therebetween, pressing the top surfaces of the second set of dies together until substantially in contact with one another so that the pre-form deforms to fill the second mold cavity formed therebetween to thereby form the tissue holding device having the predetermined shape, wherein the predetermined shape includes a core extending along a length thereof, and a plurality of tissue holding elements extending outwardly therefrom along at least a portion of the length.

2. The method according to claim 1, wherein the core has an outermost dimension of less than or equal to 0.02 inches.

3. The method according to claim 2, wherein the plurality of tissue holding elements have a length less than or equal to 0.2 inches.

4. The method according to claim 1, wherein the plurality of tissue holding elements include at least first and second tissue holding elements positioned opposite one another at substantially the same location along the length of the core.

5. The method according to claim 1, wherein the plurality of tissue holding elements extend outwardly from the core at an angle, and wherein the tissue holding device further includes a web-like portion extending between an inner side of the tissue holding elements and the core, wherein the web-like portion is thinner than the tissue holding element.

6. A method for forming a tissue holding device having a predetermined shape suitable for surgical applications comprising:

providing first and second female dies each having respective first and second top surfaces with first and second recesses formed therein, wherein the first and second recesses are sized and shaped such that, when aligned with one another, they together form a mold cavity defining the predetermined shape, wherein the predetermined shape includes a core extending along a length thereof, and a plurality of tissue holding elements extending outwardly from the core;

providing a polymeric feedstock material;

placing the feedstock material between the top surfaces of the first and second dies;

with the feedstock material therebetween, pressing the top surfaces of the first and second dies together until the top surfaces of the first and second dies are substantially in contact with one another and the recesses of the first and second dies substantially aligned to form the mold cavity, so that the feedstock material deforms and fills the cavity therebetween to thereby form the tissue holding device having the predetermined shape.

7. The method according to claim 6, wherein the core has an outermost dimension less than or equal to 0.02 inches.

8. The method according to claim 7, wherein the plurality of tissue holding elements have a length less than or equal to 0.2 inches.

9. The method according to claim 6, wherein the plurality of tissue holding elements include a plurality of sets of first and second tissue holding elements, wherein for each set the first and second tissue holding elements are positioned substantially opposite one another at substantially the same location along the length of the core.

10. A tissue holding device produced in accordance with the method of claim 6, wherein the core of the tissue holding device has a cross-sectional shape comprising opposing upper and lower outwardly curved sides and opposing first and second substantially flat lateral sides.

11. The device according to claim 10, wherein the plurality of tissue holding elements extend outwardly from the first and/or second lateral sides.

12. The device according to claim 10, wherein the tissue holding elements have a length less than or equal to 0.2 inches.

13. The device according to claim 10, wherein the core has an outmost cross-sectional dimension of less than or equal to 0.02 inches.

14. A device produced in accordance with the method of claim 6, wherein at least one of the plurality of tissue holding elements has a web-like portion extending between an inner side of the tissue holding element and the core.

15. A device produced in accordance with the method of claim 6, wherein at least one of the plurality of tissue holding elements has an inner side having a recess therein.

16. A device produced in accordance with the method of claim 6, wherein the core has a cross-section that increases in size along at least a portion of the length of the device.

17. A method for forming a tissue holding device having a predetermined shape suitable for use in surgical applications, comprising:

providing a polymeric feedstock material;

using a first set of dies, press forming the polymeric feedstock material into a pre-form;

providing a receiver plate and a stripper plate each having a top surface with a recess formed therein having a three-dimensional shaped such that, when the recesses are aligned and facing one another, a cavity is formed therebetween capable of receiving therein the pre-form and having a substantially complementary shape as that of the pre-form, the stripper plate further having a opening therethrough for receiving a punch;

aligning the receiver and stripper plates and placing the pre-form in the cavity formed therebetween;

providing a punch having a punch element having an outer periphery substantially identical to an outer periphery of the predetermined shape of the tissue holding device, and having a three dimensional surface contour substantially complementary to a top surface of a portion of the pre-form to be punched;

pressing the punch element through the stripper plate and into the pre-form to thereby create the tissue holding device of the predetermined shape;

wherein the predetermined shape of the tissue holding device includes a core extending along a length thereof, and a plurality of tissue holding elements extending outwardly therefrom along at least a portion of the length.

18. The method according to claim 17, wherein the pre-form has a central portion and first and second enlarged distal ends, and wherein the punch element presses into only the central portion of the pre-form.

19. A tissue holding device produced in accordance with the method of claim 17, wherein the core has an outermost cross-sectional dimension of less than or equal to 0.02 inches.

20. The tissue holding device according to claim 19, wherein the tissue holding elements have a length less than or equal to 0.02 inches.

21. The tissue holding device according to claim 19, wherein the core has a cross-sectional shape comprising upper and lower outwardly curved sides and opposing first and second substantially flat lateral sides.

22. The tissue holding device according to claim 21, wherein the plurality of tissue holding elements extend outwardly from the first and/or second lateral sides.

23. The tissue holding device according to claim 22, further comprising a plurality of sets of first and second tissue holding elements, wherein for each set the first and second holding elements are positioned substantially opposite one another at substantially the same location along the length of the core.

24. The tissue holding device according to claim 19, wherein the core has a substantially uniform cross-section along its length.

25. The tissue holding device according to claim 19, wherein the core increases in cross-section along at least a portion of its length.

26. The tissue holding device according to claim 19, wherein at least one of the plurality of tissue holding elements has an inner side having a recess therein.

27. The tissue holding device according to claim 19, wherein a length of the tissue grasping elements increases along at least a portion of the length of the tissue holding device.