Apparatus and method for producing braided suture products

An apparatus for braiding fine denier yarns to form a braided suture product which comprises:

• a) a frame;
• b) means associated with the frame for supporting a plurality of bobbins containing fine denier yarns;
• c) means for directing the plurality of bobbins through predetermined paths while dispensing yarn from each bobbin toward a common braiding zone to form an elongated product of braid construction;
• d) means to apply tension to the finished braided product and thereby to the fine denier yarns;
• e) means to control the applied tension on the fine denier yarns to about 7 grams or less;
• and
• f) a pair of take-up rollers positioned downstream of the braiding zone for directing finished braided product toward a take-up spool for winding thereabout, each take-up roller defining a grooved surface having a substantially V-shaped cross-sectional configuration for reception of braided products of a plurality of sizes.

An apparatus for continuously braiding fine denier yarns made of fine filaments to form a final braided suture product which comprises:

• a) a frame;
• b) a plurality of bobbin holders;
• c) a bobbin holder support for supporting the plurality of bobbin holders, each holder supporting a bobbin containing fine denier yarn;
• d) means for directing the plurality of bobbin holders and the bobbins thorough predetermined paths while dispensing yarn from each bobbin;
• e) a first yarn guide fixed with respect to each bobbin holder to receive and guide the fine denier yarn from the bobbin;
• f) a second yarn guide associated with each bobbin holder and positioned and adapted for reception and guiding of the fine denier yarn from the first yarn guide toward a common braiding zone;
• g) means for applying controlled tension to the final braided product while causing the tension to be transferred to the individual fine denier yarns prior to formation of the final braided suture product;
• h) means associated with each second yarn guide to control the tension on the fine denier yarns to about 7 grams or less as the yarn is dispensed from the associated bobbin so as to permit braiding the yarns without breakage of the fine filaments;
• and
• i) a pair of take-up rollers positioned downstream of the braiding zone for directing finished braided product toward a take-up spool for braiding thereabout.

An apparatus for braiding fine denier yarns made of filaments of less than 6 denier to form a braided suture product at speeds of 13 to 15 meters per hour, which comprises:

• a) a frame;
• b) a plurality of yarn carriers associated with the frame, each yarn carrier supporting a bobbin containing yarn made of filaments of less than 6 denier;
• c) means for directing the plurality of yarn carriers and the bobbins through predetermined paths while dispensing yarn from each bobbin toward a common braiding zone at a rate sufficient to form 13 to 15 meters of elongated sheath of braided suture product per hour;
• d) a first ceramic eyelet yarn guide fixed with respect to each yarn carrier to receive and guide the fine denier yarn from the respective associated bobbin;
• e) a take-up spool for receiving the finished braided product, the spool applying controlled tension to the finished braided suture product within predetermined limits and thereby applying tension to the yarns prior to formation of the finished braided suture product so as to permit braiding the yarns in a manner to have a predetermined construction and appearance;
• f) a second ceramic eyelet yarn guide associated with each yarn carrier, the second yarn guide receiving and guiding the fine denier yarn from the first yarn guide, the second yarn guide being attached to a pivotal arm at one end, the pivotal arm at the opposite end being in engagement with a pin which engages a coil spring, the pin being attached to a pawl adapted to be selectively received by a corresponding slot in a lower portion of the respective bobbin such that the respective bobbin is prevented from releasing yarn by engagement of the pawl with the slot until the yarn tension exceeds 5 to 7 grams;
• g) a third ceramic eyelet yarn guide to receive the yarn from the second yarn guide and to direct the yarn to the common braiding zone;
• and
• h) a pair of take-up rollers positioned downstream of the braiding zone for directing finished braided product toward the take-up spool for winding thereabout.

A method of braiding fine denier yarns to form a braided suture product which comprises:

• a) supporting a plurality of yarns carriers on a frame, each yarn carrier supporting a bobbin containing fine denier yarn made of filaments of less than 6 denier;
• b) directing the plurality of yarn carriers and the bobbins through intersecting undulating paths while dispensing yarn from each bobbin toward a common braiding zone at speeds sufficient to form an elongated sheath of braid construction at a rate of 13 to 15 meters per hour;
• c) directing the yarn to a first yarn guide fixed with respect to each the yarn carrier;
• d) directing the yarn from the first yarn guide to a second yarn guide associated with each yarn carrier and positioned and adapted for reception and guiding of the yarn from the first yarn guide, the second yarn guide being resiliently movable in response to tension of the yarn to control tension on the yarn to about 7 grams or less;
• e) directing the yarn from the second resiliently movable yarn guide to a third yarn guide fixed with respect to the yarn carrier whereby the yarn is guided toward the common braiding zone;
• f) winding the braided product about a pair of grooved take-up rollers to stabilize the finished braided product;
• g) winding the finished braided product about a take-up spool;
• and
• h) applying controlled force to the take-up spool and thereby applying controlled tension to the finished braided product within predetermined limits in a manner to transfer the tension to the individual yarns prior to formation of the finished braided product.

A method of braiding fine denier yarns to form a braided suture product which comprises:

• a) providing a main carrier support plate having a pair of undulating guide channels intersecting each other for guiding a plurality of yarn carriers;
• b) supporting a plurality of yarn carriers on the main carrier support plate, each carrier supporting a bobbin for dispensing fine yarn made of filaments of less than 6 denier;
• c) directing the yarn carriers over intersecting paths corresponding to the shape of the guide channels, a first set of the carriers being directed in a first direction and a second set of the carriers being directed in the opposite direction, the yarn carriers being directed over the paths at speeds sufficient to form a braided suture product at speeds of 13 to 15 meters per hour;
• d) guiding the fine denier yarn from each bobbin by first guide means fixed with respect to the associated yarn carrier;
• e) guiding the fine denier yarn by second guide means associated with each yarn carrier;
• f) permitting the second guide means to move in response to yarn tension in a manner to dispense yarn from the bobbin in response to tension in the yarn;
• g) receiving the yarns in a common braiding zone while the yarn carriers are directed through the intersecting paths to form a braided product from the yarns;
• h) stabilizing the braided product by winding the product about a pair of take-up rollers, each take-up roller having a grooved surface for reception of the braided product;
• and
• i) winding the stabilized braided product about a take-up spool which applies predetermined tension to each fine denier yarn;
• and
• j) controlling the tension on each fine denier yarn to about 7 grams or less;
• and
• k) controlling the tension on the braided product to permit formation of a product of predetermined construction and appearance.

An apparatus for braiding fine denier yarns to form a braided suture product which comprises:

• a) a frame;
• b) a main carrier support plate having a pair of undulating guide channels intersecting each other for guiding a plurality of yarn carriers;
• c) a plurality of individual carrier support plates positioned on the main carrier support plate, the individual carrier support plates being supported by a plurality of carrier transfer plates positioned adjacent each other and adapted for rotation, each carrier transfer plate being geared for rotation in a direction opposite the direction of rotation of the next adjacent individual carrier support plate and disposed adjacent each other along a circular path, each carrier support plate including at least two downwardly extending guide members dimensioned and configured to be positioned within at least one of the guide channels in the main carrier support plate for guiding the individual carrier support plate and the carrier along a path defined by the guide channel, each individual carrier transfer plate defining four cut-out portions spaced about 90.degree. from each other for reception of a yarn carrier as the individual carrier support plates rotate adjacent each other, each individual carrier support plate being arranged to receive a member attached to at least one of a first set of carriers within a cut-out portion to cause the carrier to travel with the cut-out portion approximately 180.degree. rotation of the carrier transfer plate for transfer of the carrier to a next adjacent individual carrier support plate rotating in a direction opposite the first carrier support plate whereby the carrier traverses an undulating path as defined by one of the guide channels in the main carrier support plate as the carrier is transferred from each carrier transfer plate to the next adjacent carrier transfer plate, each carrier transfer plate being arranged to receive at least one of a second set of carriers within the cut-out portions in a manner to cause each of the second set of carriers to traverse the second of the undulating paths defined by the guide channels in the main carrier support plate such that the second set of yarn carriers traverses a path which intersects with the path followed by the first set of yarn carriers in a direction opposite the first set of carriers;
• d) a plastic insert member provided between the carrier transfer plates and the carriers to maintain noise produced by engagement of the transfer plates within predetermined levels;
• e) a plurality of yarn carriers supported on the carrier support and transfer plates, each carrier supporting a bobbin for dispensing fine denier yarn;
• f) means positioned above the yarn carriers for reception of the yarns in a common braiding zone while the yarn carriers are directed through the intersecting paths to form an elongated braided product from the yarns;
• g) means for applying controlled tension to the final braided product while permitting the tension to be transferred to the individual fine denier yarns prior to formation of the final braided product;
• h) means for controlling the tension of the final braided product within predetermined ranges to permit formation of a braided product of predetermined construction and appearance;
• and
• i) a pair of take-up rollers positioned downstream of the braiding zone for directing finished braided product toward a take-up spool for winding thereabout.

An apparatus for braiding fine denier yarns to form a braided suture product which comprises:

• a) a frame;
• b) a main carrier support plate having a pair of undulating guide channels intersecting each other for guiding a plurality of yarn carriers;
• c) a plurality of yarn carriers supported on the main carrier support plate, each for supporting a bobbin for dispensing fine denier yarn, the bobbins being rotatable on the yarn carriers for dispensing yarns to a common braiding zone;
• d) means for directing the yarn carriers over first and second intersecting paths corresponding to the shape of the guide channels, a first set of the carriers being directed in a first direction along a first of the paths and a second set of the carriers being directed in the opposite direction along a second of the paths;
• e) means positioned above the yarn carriers for reception of the yarns in the common braiding zone while the yarn carriers are directed through the intersecting paths to form a braided product from the yarns;
• f) means positioned above the braiding zone for reception of the final braided product;
• g) means associated with the braided product reception means for applying tension to the final braided product while permitting the tension to be applied to the individual yarns;
• h) means on each of the yarn carriers to control the tension of the fine denier yarns to about 7 grams or less as they are dispensed;
• and
• i) a pair of take-up rollers positioned downstream of the braiding zone for directing finished braided product toward a take-up spool for winding thereabout.