Electrically weldable suture material, and apparatus and method for forming welded suture loops and other welded structures

A medical device for applying a suture to tissue, comprising:

• a jaw assembly, a gripping assembly, an electrode assembly, and an actuation mechanism coupled to the jaw assembly, to the gripping assembly, and to the electrode assembly;
• the jaw assembly comprising a first jaw member and a second jaw member,
• the first jaw member comprising a first tip and a first passageway for the suture,
• the second jaw member comprising a second tip and a second passageway for the suture,
• at least one of the first and second jaw members being movable between an open position and a closed position,
• the open position being a position in which the first and second tips of the first and second jaw members are separated by a gap, and
• the closed position being a position in which the first and second passageways of the first and second jaw members form a continuous passageway for the suture;
• the gripping assembly comprising a first gripper and a second gripper,
• the first gripper comprising a first gripping surface,
• the second gripper comprising a second gripping surface,
• at least one of the first and second grippers being movable between a release position and a gripping position,
• the release position being a position in which the first and second gripping surfaces of the first and second grippers are separated from one another by a gap larger than a diameter of the suture, and
• the gripping position being a position in which the first and second gripping surfaces of the first and second grippers are separated from one another by a distance smaller than the diameter of the suture;
• the electrode assembly comprising an electrode configured to apply an electric potential to the suture clamped between the first and second gripping surfaces of the first and second grippers,
• the electrode being movable between a welding position and a non-weld position,
• the welding position being a position in which the electrode engages the suture between the first and second gripping surfaces of the first and second grippers, and
• the non-weld position being a position in which the electrode is spaced from the suture between the first and second gripping surfaces of the first and second grippers;
• and
• the actuation mechanism actuatable in response to movement of the at least one of the first and second jaw members of the jaw assembly so as to selectively actuate the gripping assembly and the electrode assembly such that in the conditions the electrode assembly is in the non-weld position, the gripping assembly is in the release position, the jaw assembly is in the closed position, and the suture is positioned between the first and second gripping surfaces of the gripping assembly, progressive movement of at least one of the first and second jaw members towards the open position causes the actuation mechanism to, sequentially,
• move at least one of the first and second grippers from the release position to the gripping position, then
• move the electrode from the non-weld position to the welding position, and then
• move at least one of the first and second grippers from the gripping position to the release position.

A method for applying suture to tissue, wherein the suture comprises a biocompatible, electrically conductive thermoplastic material having a diameter, the method comprising:

• providing an apparatus comprising:
• a shaft;
• a jaw assembly comprising a first jaw member comprising a first tip and a first passageway for slidably receiving the suture, and a second jaw member comprising a second tip and a second passageway for slidably receiving the suture, wherein at least one of the first and second jaw members is pivotally mounted so as to be movable between (i) at least one open position in which the first and second tips of the first and second jaw members are separated from one another by a gap thereby defining at least one open position of the jaw assembly, and (ii) a closed position in which the first and second passageways form a continuous pathway thereby defining a closed position of the jaw assembly;
• a gripping assembly comprising a first gripper comprising a first gripping surface, and a second gripper comprising a second gripping surface, wherein at least one of the first and second grippers is movably mounted to the shaft so as to be movable between (i) a release position in which the first and second gripping surfaces of the first and second grippers are separated from one another by a gap which is larger than the diameter of the suture which is to be used to form a loop of the suture, and (ii) a gripping position in which the first and second gripping surfaces of the first and second grippers are separated from one another by a distance which is less than the diameter of the suture which is used to form the loop of the suture;
• an electrode assembly comprising an electrode for selectively applying an electric potential to the suture clamped between the first and second gripping surfaces of the first and second grippers, wherein the electrode is movably mounted to the shaft so as to be movable between (i) a non-weld position in which the electrode is spaced from the suture clamped between the first and second gripping surfaces of the first and second grippers, and (ii) a welding position in which the electrode engages the suture clamped between the first and second gripping surfaces of the first and second grippers;
• and
• an actuation mechanism actuatable in response to movement of the at least one of the first and second jaw members of the jaw assembly so as to selectively operating the gripping assembly and the electrode assembly in response to movement of at least one of the first and second jaw members of the jaw assembly, wherein, in the conditions the electrode assembly is in the non-weld position, the gripping assembly is in the release position, the jaw assembly is in the closed position, and the suture is positioned between the first and second gripping surfaces of the gripping assembly, progressive movement of the at least one of the first and second jaw members of the jaw assembly towards the at least one open position causes the actuation mechanism to, sequentially:
• (a) move at least one of the first and second grippers from the release position to the gripping position;
• (b) move the electrode from the non-weld position to the welding position;
• and
• (c) move at least one of the first and second grippers from the gripping position to the release position;
• positioning the apparatus adjacent to the tissue while (i) the jaw assembly is in the at least one open position, (ii) the gripping assembly is in the release position and (iii) the electrode assembly is in the non-weld position;
• moving at least one of the first and second jaw members so that the jaw assembly is in the closed position;
• advancing the suture through the continuous pathway so that the suture forms a loop of suture;
• and
• progressively moving the at least one of the first and second jaw members of the jaw assembly towards the at least one open position causing the actuation mechanism to, sequentially:
• (a) move at least one of the first and second grippers from the release position to the gripping position;
• (b) move the electrode from the non-weld position to the welding position;
• and
• (c) move at least one of the first and second grippers from the gripping position to the release position.