Wound closure devices such as sutures, staples and tacks have been widely used in superficial and deep surgical procedures in humans and animals for closing wounds, repairing traumatic injuries or defects, joining tissues together (bringing severed tissues into approximation, closing an anatomical space, affixing single or multiple tissue layers together, creating an anastomosis between two hollow/luminal structures, adjoining tissues, attaching or reattaching tissues to their proper anatomical location), attaching foreign elements to tissues (affixing medical implants, devices, prostheses and other functional or supportive devices), and for repositioning tissues to new anatomical locations (repairs, tissue elevations, tissue grafting and related procedures) to name but a few examples.
Sutures are often used as wound closure devices. Sutures typically consist of a filamentous suture thread attached to a needle with a sharp point. Suture threads can be made from a wide variety of materials including bioabsorbable (i.e., that break down completely in the body over time), or non-absorbable (permanent; non-degradable) materials. Absorbable sutures have been found to be particularly useful in situations where suture removal might jeopardize the repair or where the natural healing process renders the support provided by the suture material unnecessary after wound healing has been completed; as in, for example, completing an uncomplicated skin closure. Non-degradable (non-absorbable) sutures are used in wounds where healing may be expected to be protracted or where the suture material is needed to provide physical support to the wound for long periods of time; as in, for example, deep tissue repairs, high tension wounds, many orthopedic repairs and some types of surgical anastomosis. Also, a wide variety of surgical needles are available, and the shape and size of the needle body and the configuration of the needle tip is typically selected based upon the needs of the particular application.
To use an ordinary suture, the suture needle is advanced through the desired tissue on one side of the wound and then through the adjacent side of the wound. The suture is then formed into a “loop” which is completed by tying a knot in the suture to hold the wound closed. Knot tying takes time and causes a range of complications, including, but not limited to (i) spitting (a condition where the suture, usually a knot) pushes through the skin after a subcutaneous closure), (ii) infection (bacteria are often able to attach and grow in the spaces created by a knot), (iii) bulk/mass (a significant amount of suture material left in a wound is the portion that constitutes the knot), (iv) slippage (knots can slip or come untied), and (v) irritation (knots serve as a bulk “foreign body” in a wound). Suture loops associated with knot tying may lead to ischemia (knots can create tension points that can strangulate tissue and limit blood flow to the region) and increased risk of dehiscence or rupture at the surgical wound. Knot tying is also labor intensive and can constitute a significant percentage of the time spent closing a surgical wound. Additional operative procedure time is not only bad for the patient (complication rates rise with time spent under anesthesia), but it also adds to the overall cost of the operation (many surgical procedures are estimated to cost between $15 and $30 per minute of operating time).
Self-retaining sutures (including one-way suture and barbed sutures) differ from conventional sutures in that self-retaining sutures possess numerous tissue retainers (such as barbs) which anchor the self-retaining suture into the tissue following deployment and resist movement of the suture in a direction opposite to that in which the retainers face, thereby eliminating the need to tie knots to affix adjacent tissues together (a “knotless” closure). Knotless tissue-approximating devices having barbs have been previously described in, for example, U.S. Pat. No. 5,374,268, disclosing armed anchors having barb-like projections, while suture assemblies having barbed lateral members have been described in U.S. Pat. Nos. 5,584,859 and 6,264,675. Sutures having a plurality of barbs positioned along a greater portion of the suture are described in U.S. Pat. No. 5,931,855, which discloses a unidirectional barbed suture, and U.S. Pat. No. 6,241,747, which discloses a bidirectional barbed suture. Methods and apparatus for forming barbs on sutures have been described in, for example, U.S. Pat. Nos. 6,848,152. Self-retaining systems for wound closure also result in better approximation of the wound edges, evenly distribute the tension along the length of the wound (reducing areas of tension that can break or lead to ischemia), decrease the bulk of suture material remaining in the wound (by eliminating knots) and reduce spitting (the extrusion of suture material—typically knots—through the surface of the skin. All of these features are thought to reduce scarring, improve cosmesis, and increase wound strength relative to wound closures using plain sutures or staples. Thus, self-retaining sutures, because such sutures avoid knot tying, allow patients to experience an improved clinical outcome, and also save time and costs associated with extended surgeries and follow-up treatments. It is noted that all patents, patent applications and patent publications identified throughout are incorporated herein by reference in their entirety.
The ability of self-retaining sutures to anchor and hold tissues in place even in the absence of tension applied to the suture by a knot is a feature that also provides superiority over plain sutures. When closing a wound that is under tension, this advantage manifests itself in several ways: (i) self-retaining sutures have a multiplicity of retainers which can dissipate tension along the entire length of the suture (providing hundreds of “anchor” points this produces a superior cosmetic result and lessens the chance that the suture will “slip” or pull through) as opposed to knotted interrupted sutures which concentrate the tension at discrete points; (ii) complicated wound geometries can be closed (circles, arcs, jagged edges) in a uniform manner with more precision and accuracy than can be achieved with interrupted sutures; (iii) self-retaining sutures eliminate the need for a “third hand” which is often required for maintaining tension across the wound during traditional suturing and knot tying (to prevent “slippage” when tension is momentarily released during tying); (iv) self-retaining sutures are superior in procedures where knot tying is technically difficult, such as in deep wounds or laparoscopic/endoscopic procedures; and (v) self-retaining sutures can be used to approximate and hold the wound prior to definitive closure. As a result, self-retaining sutures provide easier handling in anatomically tight or deep places (such as the pelvis, abdomen and thorax) and make it easier to approximate tissues in laparoscopic/endoscopic and minimally invasive procedures; all without having to secure the closure via a knot. Greater accuracy allows self-retaining sutures to be used for more complex closures (such as those with diameter mismatches, larger defects or purse string suturing) than can be accomplished with plain sutures.
A self-retaining suture may be unidirectional, having one or more retainers oriented in one direction along the length of the suture thread; or bidirectional, typically having one or more retainers oriented in one direction along a portion of the thread, followed by one or more retainers oriented in another (often opposite) direction over a different portion of the thread (as described with barbed retainers in U.S. Pat. Nos. 5,931,855 and. 6,241,747). Although any number of sequential or intermittent configurations of retainers are possible, a common form of bidirectional self-retaining suture involves a needle at one end of a suture thread which has barbs having tips projecting “away” from the needle until the transition point (often the midpoint) of the suture is reached; at the transition point the configuration of barbs reverses itself about 180° (such that the barbs are now facing in the opposite direction) along the remaining length of the suture thread before attaching to a second needle at the opposite end (with the result that the barbs on this portion of the suture also have tips projecting “away” from the nearest needle). Projecting “away” from the needle means that the tip of the barb is further away from the needle and the portion of suture comprising the barb may be pulled more easily through tissue in the direction of the needle than in the opposite direction. Put another way, the barbs on both “halves” of a typical bidirectional self-retaining suture have tips that point towards the middle, with a transition segment (lacking barbs) interspersed between them, and with a needle attached to either end.
Despite the multitude of advantages of unidirectional and bidirectional self-retaining sutures, there remains a need to improve upon the design of the suture. Specifically, several problems common to existing self-retaining sutures can be addressed by the embodiments of this invention, including, but not limited to: (i) retainers or barbs that are fragile and break or too flexible and bend back, or do not stand proud due to an insufficient ability of the material to plastically deform and as such do not properly engage when deployed in tissue; (ii) inadequate “hold” provided by the retainers for some surgical procedures; resulting in retainers or barbs do not sufficiently anchor in the surrounding tissue and “pull through;” (iii) insufficient contact between the retainers and the surrounding tissue (often occurring when the thread diameter is too small relative to the diameter of the hole created by a larger needle; this limits the ability of the retainers to contact and “grip” the surrounding tissue); (iv) breakage of the self-retaining suture during tensioning and wound approximation; (v) rotation and slippage of the retainers after deployment; and (vi) the difficulty of creating barbs on sutures of small diameter such as 6-0, 8-0, 10-0 and below. Furthermore, the creation and or deployment of retainer features of self-retaining sutures may be difficult to achieve without impairing the tensile strength of the suture.
Thus, it would be desirable to provide improved self-retaining sutures which have enhanced ability to anchor into the surrounding tissue, enhanced tissue holding capabilities, enhanced maximum load, and enhanced clinical performance. It would further be desirable to provide improved methods for making self-retaining sutures.
Accordingly, the present invention provides, improved self-retaining sutures which have enhanced ability to anchor into the surrounding tissue, enhanced tissue holding capabilities, enhanced maximum load, and enhanced clinical performance and methods for making such self-retaining sutures.
In accordance with another aspect, the present invention provides suture having surface microtexture and/or nanotexture and methods for making such suture.
In accordance with another aspect, the present invention provides self-retaining suture having surface microtexture and/or nanotexture which has an asymmetric effect on the resistance of the suture to passing through tissue in one direction compared to the other direction.
In accordance with another aspect, the present invention provides self-retaining suture having directional surface microtexture and/or nanotexture effective to secure the suture to tissue in at least one direction in the absence of macro tissue retainers such as barbs.
In accordance with another aspect, the present invention provides self-retaining suture having directional surface microtexture and/or nanotexture effective to augment the securing of the suture to tissue in at least one direction in conjunction with tissue retainers such as barbs.
In accordance with another aspect, the present invention provides self-retaining suture having surface microtexture and/or nanotexture which has an asymmetric effect on the resistance of the suture to passing through tissue in one direction compared to the other direction without adversely affecting the tensile strength of the suture.
In accordance with another aspect, the present invention provides self-retaining suture having surface microtexture and/or nanotexture which has an asymmetric effect on the resistance of the suture to passing through tissue in one direction compared to the other direction and which can be readily formed on small diameter sutures of sizes smaller than 4-0, 6-0, 7-0, 8-0, 9-0, 10-0 and 11-0.
The details of one or more embodiments are set forth in the description below. Other features, objects and advantages will be apparent from the description, the drawings, and the claims. In addition, the disclosures of all patents and patent applications referenced herein are incorporated by reference in their entirety.
Features of the invention, its nature and various advantages will be apparent from the accompanying drawings and the following detailed description of various embodiments.
Definitions of certain terms that may be used hereinafter include the following.
“Self-retaining system” refers to a self-retaining suture together with devices for deploying the suture into tissue. Such deployment devices include, without limitation, suture needles and other deployment devices as well as sufficiently rigid and sharp ends on the suture itself to penetrate tissue.
“Self-retaining suture” refers to a suture that includes features on the suture filament for engaging tissue without the need for a knot or suture anchor. As used herein the features include, for example, textural features.
“Tissue retainer” (or simply “retainer”) or “barb” refers to a physical feature of a suture filament which is adapted to mechanically engage tissue and resist movement of the suture in at least one axial directions. By way of example only, tissue retainer or retainers can include one or more of, hooks, projections, barbs, darts, extensions, bulges, anchors, protuberances, spurs, bumps, points, cogs, tissue engagers, traction devices, surface roughness, surface irregularities, surface defects, edges, facets, microtexture, nanotexture and the like. In certain configurations, tissue retainers are adapted to engage tissue to resist movement of the suture in a direction other than the direction in which the suture is deployed into the tissue by the surgeon, by being oriented to substantially face the deployment direction. In some embodiments the retainers lie flat when pulled in the deployment direction and open or “fan out” when pulled in a direction contrary to the deployment direction. As the tissue-penetrating end of each retainer faces away from the deployment direction when moving through tissue during deployment, the tissue retainers should not catch or grab tissue during this phase. Once the self-retaining suture has been deployed, a force exerted in another direction (often substantially opposite to the deployment direction) causes the retainers to be displaced from the deployment position (i.e. resting substantially along the suture body), forces the retainer ends to open (or “fan out”) from the suture body in a manner that catches and penetrates into the surrounding tissue, and results in tissue being caught between the retainer and the suture body; thereby “anchoring” or affixing the self-retaining suture in place. In certain other embodiments, the tissue retainers may be configured to permit motion of the suture in one direction and resist movement of the suture in another direction without fanning out or deploying. In certain other configurations, the tissue retainer may be configured or combined with other tissue retainers to resist motion of the suture filament in both directions. Typically a suture having such retainers is deployed through a device such as a cannula or needle which prevents contact between the retainers and the tissue until the suture is in the desired location.
“Retainer configurations” refers to configurations of tissue retainers and can include features such as size, shape, flexibility, surface characteristics, and so forth. These are sometimes also referred to as “barb configurations”.
“Bidirectional suture” refers to a self-retaining suture having retainers oriented in one direction at one end and retainers oriented in the other direction at the other end. A bidirectional suture is typically armed with a needle at each end of the suture thread. Many bidirectional sutures have a transition segment located between the two barb orientations.
“Transition segment” refers to a retainer-free (barb-free) portion of a bidirectional suture located between a first set of retainers (barbs) oriented in one direction and a second set of retainers (barbs) oriented in another direction. The transition segment can be at about the midpoint of the self-retaining suture, or closer to one end of the self-retaining suture to form an asymmetrical self-retaining suture system.
“Suture thread” refers to the filamentary body component of the suture. The suture thread may be a monofilament, or made of multiple filaments as in a braided suture. The suture thread may be made of any suitable biocompatible material, and may be further treated with any suitable biocompatible material, whether to enhance the sutures' strength, resilience, longevity, or other qualities, or to equip the sutures to fulfill additional functions besides joining tissues together, repositioning tissues, or attaching foreign elements to tissues.
“Monofilament suture” refers to a suture comprising a monofilamentary suture thread.
“Braided suture” refers to a suture comprising a multifilamentary suture thread. The filaments in such suture threads are typically braided, twisted, or woven together.
“Degradable (also referred to as “biodegradable” or “bioabsorbable”) suture” refers to a suture which, after introduction into a tissue is broken down and absorbed by the body. Typically, the degradation process is at least partially performed in a biological system.
“Degradation” refers to a chain scission process by which a polymer chain is cleaved into oligomers and monomers. Chain scission may occur through various mechanisms, including, for example, by chemical reaction (e.g., hydrolysis, oxidation/reduction, enzymatic mechanisms or a combination or these) or by a thermal or photolytic process. Polymer degradation may be characterized, for example, using gel permeation chromatography (GPC), which monitors the polymer molecular mass changes during erosion and breakdown. Degradable suture material may include polymers such as catgut, polyglycolic acid, lactic acid polymers, polyether-esters (e.g., copolymers of polyglycolide with polyglycols, polyglycolide with polyethers, polylactic acid with polyglycols or polylactic acid with polyethers), copolymers of glycolide and lactide, copolymers of trimethylene carbonate and glycolide with diethylene glycol (e.g., MAXON™, Tyco Healthcare Group), terpolymer composed of glycolide, trimethylene carbonate, and dioxanone (e.g., BIOSYN™ [glycolide (60%), trimethylene carbonate (26%), and dioxanone (14%)], Tyco Healthcare Group), copolymers of glycolide, caprolactone, trimethylene carbonate, and lactide (e.g., CAPROSYN™, Tyco Healthcare Group). These sutures can be in either a braided multifilament form or a monofilament form. The polymers used in the present invention can be linear polymers, branched polymers or multi-axial polymers. Examples of multi-axial polymers used in sutures are described in U.S. Patent Application Publication Nos. 20020161168, 20040024169, and 20040116620. Degradable sutures can also include dissolvable sutures made of a dissolvable polymer, such as a polyvinyl alcohol partly deacetylated polymer, but not limited thereto. Sutures made from degradable suture material lose tensile strength as the material degrades.
“Non-degradable (also referred to as “non-absorbable”) suture” refers to a suture comprising material that is not degraded by chain scission such as chemical reaction processes (e.g., hydrolysis, oxidation/reduction, enzymatic mechanisms or a combination or these) or by a thermal or photolytic process. Non-degradable suture material includes polyamide (also known as nylon, such as nylon 6 and nylon 6.6), polyethylene terephthlate, polytetrafluoroethylene, polyether-ester (such as polybutylene or polyethylene terepthalate based copolymers with polyglycols or polyethers), polyurethane, metal alloys, metal (e.g., stainless steel wire), polypropylene, polyethelene, silk, and cotton. Sutures made of non-degradable suture material are suitable for applications in which the suture is meant to remain permanently or is meant to be physically removed from the body.
Sutures materials are broadly classified as being degradable or bioabsorbable (i.e., they break down completely in the body over time), such as those composed of catgut, glycolic acid polymers and copolymers, lactic acid polymers and copolymers, and polyether-esters based copolymers such as polyglycolide or lactide copolymers with polyglycols or polyethers; or as being non-absorbable (permanent; nondegradable), such as those made of polyamide, polytetrafluoroethylene, polyethylene terephthalate, polyurethane, polyether-esters based copolymers such as polybutylene or polyethylene terephthalate with polyglycols or polyethers, metal alloys, metal (e.g., stainless steel wire), polypropylene, polyethelene, silk, and cotton. Degradable (bioabsorbable) sutures have been found to be particularly useful in situations where suture removal might jeopardize the repair or where the natural healing process renders the support provided by the suture material unnecessary after wound healing has been completed; as in, for example, completing an uncomplicated skin closure. Nondegradable (non-absorbable) sutures are used in wounds where healing may be expected to be protracted or where the suture material is needed to provide physical support to the wound for long periods of time; as in, for example, deep tissue repairs, high tension wounds, many orthopedic repairs and some types of surgical anastomoses.
Bioabsorbable sutures can be made of materials which are broken down in tissue after a given period of time, which depending on the material can be from ten days to eight weeks. The sutures are used therefore in many of the internal tissues of the body. In most cases, three weeks is sufficient for the wound to close firmly. At that time the suture is not needed any more, and the fact that it disappears is an advantage, as there is no foreign material left inside the body and no need for the patient to have the sutures removed. In rare cases, bioabsorbable sutures can cause inflammation and be rejected by the body rather than absorbed. Bioabsorbable sutures were first made from the intestines of mammals. For example, gut sutures can be made of specially prepared bovine or ovine intestine, and can be untreated (plain catgut), tanned with chromium salts to increase the suture persistence in the body (chromic catgut), or heat-treated to give more rapid absorption (fast catgut). Concern about transmitting diseases such as bovine spongiform encephalopathy, has resulted in the gut being harvested from stock which have been tested to determine that the natural polymers used as suture materials do not carry viral diseases. Bioabsorbable sutures can be made of synthetic polymer fibers, which can be monofilaments or braided.
“Suture diameter” refers to the diameter of the body of the suture. It is to be understood that a variety of suture lengths may be used with the sutures described herein and that while the term “diameter” is often associated with a circular periphery, it is to be understood herein to indicate a cross-sectional dimension associated with a periphery of any shape. Suture sizing is based upon diameter. United States Pharmacopeia (“USP”) designation of suture size runs from 0 to 7 in the larger range and 1-0 to 11-0 in the smaller range; in the smaller range, the higher the value preceding the hyphenated zero, the smaller the suture diameter. The actual diameter of a suture will depend on the suture material, so that, by way of example, a suture of size 5-0 and made of collagen will have a diameter of 0.15 mm, while sutures having the same USP size designation but made of a synthetic absorbable material or a non-absorbable material will each have a diameter of 0.1 mm. The selection of suture size for a particular purpose depends upon factors such as the nature of the tissue to be sutured and the importance of cosmetic concerns; while smaller sutures may be more easily manipulated through tight surgical sites and are associated with less scarring, the tensile strength of a suture manufactured from a given material tends to decrease with decreasing size. It is to be understood that the sutures and methods of manufacturing sutures disclosed herein are suited to a variety of diameters, including without limitation 7, 6, 5, 4, 3, 2, 1, 0, 1-0, 2-0, 3-0, 4-0, 5-0, 6-0, 7-0, 8-0, 9-0, 10-0 and 11-0.
“Suture deployment end” refers to an end of the suture to be deployed into tissue; one or both ends of the suture may be suture deployment ends. The suture deployment end may be attached to a deployment device such as a suture needle, or may be sufficiently sharp and rigid to penetrate tissue on its own.
“Armed suture” refers to a suture having a suture needle on at least one suture deployment end.
“Needle attachment” refers to the attachment of a needle to a suture requiring same for deployment into tissue, and can include methods such as crimping, swaging, using adhesives, and so forth. The suture thread is attached to the suture needle using methods such as crimping, swaging and adhesives. Attachment of sutures and surgical needles is described in U.S. Pat. Nos. 3,981,307, 5,084,063, 5,102,418, 5,123,911, 5,500,991, 5,722,991, 6,012,216, and 6,163,948, and U.S. Patent Application Publication No. US 2004/0088003). The point of attachment of the suture to the needle is known as the swage.
“Suture needle” refers to needles used to deploy sutures into tissue, which come in many different shapes, forms and compositions. There are two main types of needles, traumatic needles and atraumatic needles. Traumatic needles have channels or drilled ends (that is, holes or eyes) and are supplied separate from the suture thread and are threaded on site. Atraumatic needles are eyeless and are attached to the suture at the factory by swaging or other methods whereby the suture material is inserted into a channel at the blunt end of the needle which is then deformed to a final shape to hold the suture and needle together. As such, atraumatic needles do not require extra time on site for threading and the suture end at the needle attachment site is generally smaller than the needle body. In the traumatic needle, the thread comes out of the needle's hole on both sides and often the suture rips the tissues to a certain extent as it passes through. Most modern sutures are swaged atraumatic needles. Atraumatic needles may be permanently swaged to the suture or may be designed to come off the suture with a sharp straight tug. These “pop-offs” are commonly used for interrupted sutures, where each suture is only passed once and then tied. For barbed sutures that are uninterrupted, these atraumatic needles are preferred.
Suture needles may also be classified according to the geometry of the tip or point of the needle. For example, needles may be (i) “tapered” whereby the needle body is round and tapers smoothly to a point; (ii) “cutting” whereby the needle body is triangular and has a sharpened cutting edge on the inside; (iii) “reverse cutting” whereby the cutting edge is on the outside; (iv) “trocar point” or “taper cut” whereby the needle body is round and tapered, but ends in a small triangular cutting point; (v) “blunt” points for sewing friable tissues; (vi) “side cutting” or “spatula points” whereby the needle is flat on top and bottom with a cutting edge along the front to one side (these are typically used for eye surgery).
Suture needles may also be of several shapes including, (i) straight, (ii) half curved or ski, (iii) ¼ circle, (iv) ⅜ circle, (v) ½ circle, (vi) ⅝ circle, (v) and compound curve.
Suturing needles are described, for example, in U.S. Pat. Nos. 6,322,581 and 6,214,030 (Mani, Inc., Japan); and 5,464,422 (W. L. Gore, Newark, Del.); and 5,941,899; 5,425,746; 5,306,288 and 5,156,615 (US Surgical Corp., Norwalk, Conn.); and 5,312,422 (Linvatec Corp., Largo, Fla.); and 7,063,716 (Tyco Healthcare, North Haven, Conn.). Other suturing needles are described, for example, in U.S. Pat. Nos. 6,129,741; 5,897,572; 5,676,675; and 5,693,072. The sutures described herein may be deployed with a variety of needle types (including without limitation curved, straight, long, short, micro, and so forth), needle cutting surfaces (including without limitation, cutting, tapered, and so forth), and needle attachment techniques (including without limitation, drilled end, crimped, and so forth). Moreover, the sutures described herein may themselves include sufficiently rigid and sharp ends so as to dispense with the requirement for deployment needles altogether.
“Needle diameter” refers to the diameter of a suture deployment needle at the widest point of that needle. While the term “diameter” is often associated with a circular periphery, it is to be understood herein to indicate a cross-sectional dimension associated with a periphery of any shape.
“Wound closure” refers to a surgical procedure for closing of a wound. An injury, especially one in which the skin or another external or internal surface is cut, torn, pierced, or otherwise broken is known as a wound. A wound commonly occurs when the integrity of any tissue is compromised (e.g., skin breaks or burns, muscle tears, or bone fractures). A wound may be caused by an act, such as a puncture, fall, or surgical procedure; by an infectious disease; or by an underlying medical condition. Surgical wound closure facilitates the biological event of healing by joining, or closely approximating, the edges of those wounds where the tissue has been torn, cut, or otherwise separated. Surgical wound closure directly apposes or approximates the tissue layers, which serves to minimize the volume new tissue formation required to bridge the gap between the two edges of the wound. Closure can serve both functional and aesthetic purposes. These purposes include elimination of dead space by approximating the subcutaneous tissues, minimization of scar formation by careful epidermal alignment, and avoidance of a depressed scar by precise eversion of skin edges.
“Tissue elevation procedure” refers to a surgical procedure for repositioning tissue from a lower elevation to a higher elevation (i.e. moving the tissue in a direction opposite to the direction of gravity). The retaining ligaments of the face support facial soft tissue in the normal anatomic position. However, with age, gravitational effects and loss of tissue volume effect downward migration of tissue, and fat descends into the plane between the superficial and deep facial fascia, thus causing facial tissue to sag. Face-lift procedures are designed to lift these sagging tissues, and are one example of a more general class of medical procedure known as a tissue elevation procedure. More generally, a tissue elevation procedure reverses the appearance change that results from effects of aging and gravity over time, and other temporal effects that cause tissue to sag, such as genetic effects. It should be noted that tissue can also be repositioned without elevation; in some procedures tissues are repositioned laterally (away from the midline), medially (towards the midline) or inferiorly (lowered) in order to restore symmetry (i.e. repositioned such that the left and right sides of the body “match”).
“Medical device” or “implant” refers to any object placed in the body for the purpose of restoring physiological function, reducing/alleviating symptoms associated with disease, and/or repairing and/or replacing damaged or diseased organs and tissues. While normally composed of biologically compatible synthetic materials (e.g., medical-grade stainless steel, titanium and other metals or polymers such as polyurethane, silicon, PLA, PLGA and other materials) that are exogenous, some medical devices and implants include materials derived from animals (e.g., “xenografts” such as whole animal organs; animal tissues such as heart valves; naturally occurring or chemically-modified molecules such as collagen, hyaluronic acid, proteins, carbohydrates and others), human donors (e.g., “allografts” such as whole organs; tissues such as bone grafts, skin grafts and others), or from the patients themselves (e.g., “autografts” such as saphenous vein grafts, skin grafts, tendon/ligament/muscle transplants). Medical devices that can be used in procedures in conjunction with the present invention include, but are not restricted to, orthopedic implants (artificial joints, ligaments and tendons; screws, plates, and other implantable hardware), dental implants, intravascular implants (arterial and venous vascular bypass grafts, hemodialysis access grafts; both autologous and synthetic), skin grafts (autologous, synthetic), tubes, drains, implantable tissue bulking agents, pumps, shunts, sealants, surgical meshes (e.g., hernia repair meshes, tissue scaffolds), fistula treatments, spinal implants (e.g., artificial intervertebral discs, spinal fusion devices, etc.) and the like.
This application also uses the terms proximal and distal in the conventional manner when describing an implant and/or suture. Thus, proximal refers to the end or side of a device or component closest to the hand operating the device, whereas distal refers to the end or side of a device furthest from the hand operating the device. For example, the needle end of a suture would conventionally be called the proximal end (it is closest to the surgeon) while the far end of the suture would be termed the distal end. For a bidirectional self-retaining suture the proximal end refers to the needle end of whichever arm is being deployed.
In the description that follows, common reference numerals are used to indicate like elements throughout the drawings and detailed description; therefore, reference numerals used in a drawing may or may not be referenced in the detailed description specific to such drawing if the associated element is described elsewhere. The first digit in a three digit reference numeral indicates the series of figures in which the referenced item first appears. Likewise the first two digits in a four digit reference numeral.
As discussed above, the present invention provides compositions, configurations, methods of manufacturing and methods of using self-retaining systems in surgical procedures which increase the ability of the self-retaining sutures to anchor into the surrounding tissue to provide superior holding strength and improve clinical performance. In accordance with one embodiment, the present invention provides a variety of surface configurations for sutures where those configurations enhance or diminish the ability of a suture to move through tissue. The surface configurations include directional and non-directional microtextures and/or nanotextures. For example, in order to resist the movement of the suture through tissue, the surface may have a tire-tread appearance. The microtexture and/or nanotexture is, in some embodiments, designed to reduce the resistance to movement of the suture through tissue. The microtexture and/or nanotexture is, in some embodiments, designed to achieve a larger resistance of the suture to movement of the suture through tissue in a deployment direction as compared to a reverse direction. The microtexture and/or nanotexture can be created using a variety of methods including, for example, laser ablation, nanomolding, chemical ablation (e.g., as done in lithography), mechanical cutting, and coining. Alternatively a material, retainer, scale, sheath, sleeve having a desired surface configuration can be secured to a suture thread.
A break is shown in each of regions 140, 142, 144, 146 and 148 to indicate that the length of each region may be varied and selected depending upon the application for which the suture is intended to be used. Although a bidirectional self-retaining suture system 100 is illustrated, the present invention includes self-retaining suture systems of a wide variety of retainer and needle configurations as described above. Likewise, although needles 110 and 112 are shown as curved needles, needles 110 and 112 can be any of the range of different surgical needles developed for use in different applications. Needles 110 and 112 may have the same configuration or different configurations.
Additionally, in many procedures it is desirable to locate the transition region in order to properly situate the transition region at the beginning of suture deployment. Thus, the filament 120 in section 144 is, in some embodiments, provided with an identifiable feature. For example, as shown in
In alternative embodiments, a pledget can be applied to a self-retaining suture system.
A directional surface microtexture and/or nanotexture typically includes an arrangement of textural features distributed on the surface 202 of a filament 200. The arrangement can be a regular arrangement in some embodiments and an irregular and/or random arrangement in other embodiments. The textural features are in some embodiments made by subtracting material from the surface 202 of the suture filament 200 (e.g. laser machining). In other embodiments material is added to the surface 202 of suture filament 200 to create textural features (e.g. nanomolding added material). In still other embodiments, the material at the surface 202 of suture filament 200 is treated/manipulated to create textural features (e.g. coining/imprinting). The material is in some embodiments the same as the material of the suture filament and in other embodiments is different the material of the suture filament. In other embodiments the surface 202 of the suture filament 200 is treated so that it changes shape to form textural features. In other embodiments combinations of one or more of the processes of adding material to the surface, subtracting material from the surface and treating the surface is performed in any order to create textural features.
Microtexture, as used herein, refers to a texture consisting of features (microfeatures) having one or more characteristic dimensions less than about 10 μm and greater than 1 μm. Nanotexture conventionally refers to textures consisting of features (nanofeatures) having one or more characteristic dimensions smaller than 1000 nm. Such features are in some embodiments larger in one or more dimensions, for example, a groove of a microtexture can have a width and depth less than 10 μm but a length much longer than 10 μm. Likewise a ridge of a nanotexture can have a width and depth less than 1000 nm but a length much longer than 1000 nm.
Microtextures and/or nanotextures are known to effect changes in the surface tissue interaction including for example, adhesion, wettability, tissue ingrowth, tissue engagement, chemistry, stiction and friction. A directional microtexture and/or nanotexture as used herein refers to an arrangement of microfeatures and/or nanofeatures wherein an aspect of the shape and/or orientation and/or distribution of the microfeatures and/or nanofeatures causes the surface bearing the texture to have a greater resistance to movement through tissue in one direction compared to another direction as will be described with respect to the particular embodiments of microtextures and nanotextures disclosed below. Generally, a directional microtexture and/or nanotexture will have an asymmetry with respect to an aspect of the shape and/or orientation and/or distribution of the microfeatures and/or nanofeatures. With respect to a self-retaining suture the directional microtexture and/or nanotexture causes the filament to have less resistance to passing through tissue in the forward direction along the longitudinal axis L (in the direction of deployment) compared to the reverse direction along the longitudinal axis L (against the direction of deployment).
In particular embodiments, the present invention include suture threads and other surgical filaments having thereon directional microtexture and/or nanotexture which causes the filament to have less resistance to passing through tissue in the forward direction along the longitudinal axis L (in the direction of deployment) compared to the reverse direction along the longitudinal axis L (against the direction of deployment). Particular embodiments of such directional microtextures and nanotextures are described below.
Referring first to
In embodiments, the height of textural features 314 is less than about 10 microns. In preferred embodiments the height of textural features 314 is of the order of a micron. In alternative embodiments the height of textural features 314 is less than about a micron and greater than about 500 nanometers. The size of the textural features is significantly larger than the height in other dimensions. The width of each chevron 330 is for example, approximately an order of magnitude greater than the height of the textural features 314. In the embodiment shown in
Referring first to
In embodiments, the height of textural features 414 is less than about 10 microns. In preferred embodiments the height of textural features 414 is of the order of a micron. In alternative embodiments the height of textural features 414 is less than about a micron and greater than about 500 nanometers. The size of the textural features is significantly larger than the height in other dimensions. The width of each ridge 430 is for example, greater than an order of magnitude greater than the height of the textural features 414 and in some embodiments the width is then entire circumference of a suture thread. In the embodiment shown in
Referring first to
In embodiments, the height of textural features 514 is less than about 10 microns. In preferred embodiments the height of textural features 514 is of the order of a micron. In alternative embodiments the height of textural features 514 is less than about a micron and greater than about 500 nanometers. The size of the textural features is significantly larger than the height in some dimensions. In the embodiment shown in
Referring first to
In embodiments, the height of textural features 614 is less than about 10 microns. In preferred embodiments the height of textural features 614 is of the order of a micron. In alternative embodiments the height of textural features 614 is less than about a micron and greater than about 500 nanometers. The size of the textural features is significantly larger than the height in other dimensions. The width of each chevron 630 is for example, approximately an order of magnitude greater than the height of the textural features 614. In the embodiment shown in
Referring first to
In embodiments, the height of textural features 714 is less than about 10 microns. In preferred embodiments the height of textural features 714 is of the order of a micron. In alternative embodiments the height of textural features 714 is less than about a micron and greater than about 500 nanometers. The size of the textural features is of similar size in other dimensions. In the embodiment shown in
Referring first to
In embodiments, the depth of textural features 814 is less than about 10 microns. In preferred embodiments the depth of textural features 814 is of the order of a micron. In alternative embodiments the depth of textural features 814 is less than about a micron and greater than about 500 nanometers. The diameter of textural features 814 is of similar size to the depth. In the embodiment shown in
Referring first to
The microtexture/nanotexture shown in
As, shown in
As shown in
In the embodiment of
Textural features at the scale of 10 microns and smaller can be manufactured by a number of methods known in the art. Microtextured and nanotextured surfaces can be made by processes including, for example, chemical vapor deposition, plasma etching, wet etching, EDM, nanomolding, stamping, printing, laser-cutting; laser ablation; imprint lithography. For example, methods for creating microtextures and nanotextures on generally planar surfaces are disclosed in the following references: U.S. Patent Publication No. 2009/0250588 entitled “Nanostructured Surfaces For Biomedical/Biomaterial Applications And Processes Therefore” to Robeson et al.; U.S. Patent Publication No. 20080131692 entitled “Methods And Materials For Fabricating Laminate Nanomolds And Nanoparticles Therefrom” to Rolland et al.; U.S. Patent Publication No. 2008/0169059 entitled “Biomimetic Modular Adhesive Complex: Materials, Methods And Applications Therefore” to Messersmith et al.; United States Patent Publication No. 2007/0282247 entitled “Medical Device Applications of Nanostructured Surfaces” to Desai et al.; United States Patent Publication 2008/0248216 entitled “Methods For Preparing Nanotextured Surfaces And Applications Thereof” to Yeung et al.; United States Patent Application 2009/0082856 entitled “Medical Devices Having Nanofiber-Textured Surfaces” to Flanagan; and Mandave et al., “A biodegradable and biocompatible gecko-inspired tissue adhesive,” PNAS 105 (7) 2307-2312 (2008); and Jeong et al. “A nontransferring dry adhesive with hierarchical polymer nanohairs,” PNAS 106 (14) 5639-5644 (2009); which are incorporated herein by reference.
The above processes for creating nanotexture and microtextures on generally planar surfaces can be adapted in some respect for use on suture threads in a number of ways. In a simple embodiment, microtextured and or nanotextured films are created in a planar configuration and subsequently applied to the surface of a suture thread (see, e.g.,
In preferred embodiments of the present invention, laser-cutting and/or laser ablating techniques are utilized to remove material from the surface of a suture thread to leave the desired microtexture and/or nanotexture. For example, excimer laser machining techniques are capable of creating features with a resolution of less than 10 μm and femtosecond laser techniques (for example using a Ti:sapphire ultrafast laser) are capable of generating surface features at submicron resolution. Laser machining techniques are capable of cutting/ablating from drawn monofilaments. Monofilaments of drawn polymers are preferred materials because of their high tensile strength to diameter and their flexibility. Femtosecond laser techniques in particular are capable of forming features on monofilament sutures of USP 2-0 to 11-0 with resolutions smaller than 10 μm, 5 um, and 1 um.
In alternative embodiments, material can be added to the surface of a suture thread to create microtexture and/or nanotexture on the surface of the thread. For example, a sheath of material is, in some embodiments, extruded over a suture thread. The sheath material is then manipulated/patterned using nanomolding, coining or photolithographic techniques to generate the desired texture and/or nanotexture.
In certain embodiments the surface of the suture is also provided with a therapeutic and/or adhesive agent/coating. For example, a surface microtexture and/or nanotexture in some embodiments benefits by treatment with a chemical that facilitates interaction with tissue. Thus, other substances and materials that it would be desirable to selectively expose to the tissue in similar fashion may be applied to the suture to facilitate their delivery to the desired targets. For example therapeutic compositions including, for example, compositions to promote healing and prevent undesirable effects such as scar formation, infection, pain, and so forth may be in some embodiments, advantageously incorporated with the material of the suture. In such embodiments the therapeutic composition is exposed to tissue at the inner retainer surface of the retainers. This arrangement is particularly suitable for therapeutic agents selected to promote and enhance the effectiveness of the retainer. Alternatively, the therapeutic agent may be selected to ameliorate any deleterious effects upon the tissue resulting from engagement of the tissue by the retainer and to promote healing. Compositions for incorporation in the suture, microtexture and/or nanotexture may include without limitation anti-proliferative agents, anti-angiogenic agents, anti-infective agents, fibrosis-inducing agents, anti-scarring agents, lubricious agents, echogenic agents, anti-inflammatory agents, cell cycle inhibitors, analgesics, and anti-microtubule agents.
The purpose of the suture may determine the sort of therapeutic agent that is applied to the suture; for example, self-retaining sutures having anti-proliferative agents may be used in closing tumor excision sites, while self-retaining sutures with fibrosing agents may be used in tissue repositioning procedures and those having anti-scarring agents may be used for wound closure on the skin. The compositions can be incorporated in the suture, microtexture and/or nanotexture in a variety of manners, including for example: (a) by directly affixing to the suture a formulation (e.g., by either spraying the suture with a polymer/drug film, or by dipping the suture into a polymer/drug solution) where the material is selectively absorbed by the suture, microtexture and/or nanotexture where exposed on the retainers, or (b) adding the composition to the raw material of the suture, microtexture and/or nanotexture layer prior to making the filament.
Therapeutic agents may also be coated on regions of the suture or the entire suture by spraying, dipping or absorption of the agent by a hydrogel applied to the suture surface. Coatings may also include a plurality of compositions either together or on different portions of the suture, where the multiple compositions can be selected either for different purposes (such as combinations of analgesics, anti-infective and anti-scarring agents) or for the synergistic effects of the combination. Compositions for incorporation in the suture, microtexture and/or nanotexture may include, without limitation anti-proliferative agents, anti-angiogenic agents, anti-infective agents, fibrosis-inducing agents, anti-scarring agents, lubricious agents, echogenic agents, anti-inflammatory agents, cell cycle inhibitors, analgesics, and anti-microtubule agents depending upon the purpose to which the suture will be put.
In addition to the general wound closure and soft tissue repair applications, self-retaining sutures having surface microtexture and/or nanotextures can be used in a variety of other indications. Self-retaining sutures as described herein may be used in various dental procedures, i.e., oral and maxillofacial surgical procedures and thus may be referred to as “self-retaining dental sutures.” Self-retaining sutures described herein may also be used in microsurgical procedures that are performed under a surgical microscope (and thus may be referred to as “self-retaining microsutures”). Such surgical procedures include, but are not limited to, reattachment and repair of peripheral nerves, spinal microsurgery, microsurgery of the hand, various plastic microsurgical procedures (e.g., facial reconstruction), microsurgery of the male or female reproductive systems, and various types of reconstructive microsurgery. Microsurgical reconstruction is used for complex reconstructive surgery problems when other options such as primary closure, healing by secondary intention, skin grafting, local flap transfer, and distant flap transfer are not adequate. Self-retaining microsutures have a very small caliber, often as small as USP 8-0 to USP 11-0 and smaller. The microsutures may be degradable or non-degradable. Self-retaining sutures as described herein may be used in similarly small caliber ranges for ophthalmic surgical procedures and thus may be referred to as “ophthalmic self-retaining sutures”. Such procedures include but are not limited to keratoplasty, cataract, and vitreous retinal microsurgical procedures. Self-retaining sutures can also be used in a variety of veterinary applications for a wide number of surgical and traumatic purposes in animal health.
Although the present invention has been shown and described in detail with regard to only a few exemplary embodiments of the invention, it should be understood by those skilled in the art that it is not intended to limit the invention to the specific embodiments disclosed. Various modifications, omissions, and additions may be made to the disclosed embodiments without materially departing from the novel teachings and advantages of the invention, particularly in light of the foregoing teachings. Accordingly, it is intended to cover all such modifications, omissions, additions, and equivalents as may be included within the spirit and scope of the invention as defined by the following claims.
This application is a National Stage application under 35 U.S.C. 371 of PCT/US2011/035431, filed on May 5, 2011, which claims priority from U.S. Provisional Application Ser. No. 61/331,629, filed on May 5, 2010.
Filing Document | Filing Date | Country | Kind | 371c Date |
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PCT/US11/35431 | 5/5/2011 | WO | 00 | 2/7/2013 |
Number | Date | Country | |
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61331629 | May 2010 | US |