Patent Description:
A closed-loop braided textile, and methods and systems for making the closed-loop braided textile are disclosed. Certain medical applications desire a flexible textile component, such as a suture, that has a loop on the distal end of component. This loop can be used to hook onto a medical device or a device component to position the device in vivo or can be used to remove a device or component if the delivery position is not correct. Closed looped constructs have other uses such as a load transfer member in surgical instrumentation, a load transfer member as a standalone or as a component of an implantable class <NUM> or class <NUM> medical devices.

These looped-end sutures are often made by braiding a single suture length, and then looping a first terminal end of the suture back and feeding it through the side of the suture, between yarns, and into a lumen in a center lumen of the suture, pointing the direction of the opposite (i.e., second) end of the suture. If a long enough segment of the first terminal end is fed through the lumen, the hope is that during use, when a longitudinal tension is applied to the suture, that the braid of the suture will constrict upon the first terminal end - which has been fed back into the lumen of the suture - with sufficient frictional force to keep it in place despite the tension pulling on the loop.

Accordingly, improved systems and methods for bifurcating lengths of sutures are desired. Furthermore, improved methods and structures for forming looped-end sutures are desired.

<CIT> discloses a haulage sling comprising a band of substantially elliptical cross-section formed by braiding nine wires or other strands and is provided with an eye at each end, the ends of the strands after forming the respective eyes being interwoven back into the band substantially to meet one another.

<CIT> describes a method of manufacturing a biodegradable surgical suture with a distal end shaped like a loop by using a twist braider.

The present invention relates to a braided construct as defined in the appended claims. Thus, the present invention provides a braided construct comprising: a) four yarns that are braided amongst one another to form a four-strand braid on a first side of a first closed loop and a four-strand braid on a second side of the first closed loop; and b) wherein the braided first and second sides of the first closed loop converge at a first convergence point where the yarns the first and second sides are braided amongst one another into a single braid forming a first tail so that the yarns continuously extend from the first tail into the first convergence point and then into the first side of the first closed loop and then into the second side of the first closed loop (<NUM>) and then back to the convergence point and into the first tail.

More generally, methods and systems are disclosed which, although not specifically claimed, may be used to prepare a braided construct.

A method for making a braided textile suture is disclosed. The method can include loading a braiding machine with a first yarn in a first carrier and a second yarn in a second carrier. The method can include attaching the first yarn to the second yarn into a first combined yarn. The attaching the first yarn to the second yarn can be at a first attachment point The attaching can include tying, welding, epoxying, gluing, clipping, or combinations thereof, the first yarn to the second yarn. The method can include pulling the first attachment point to the first carrier The method can include placing the first combined yarn on a collector, such as an S-hook. The method can include maypole braiding the first combined yarn on a first side of the collector. The method can include maypole braiding the first combined yarn on a second side of the collector separate from the maypole braiding of the first combined yarn on the first side of the collector.

The method can also include maypole braiding the first and second yarns on both sides of the collector together in a single maypole. Before the maypole braiding of the first and second yarns on both sides of the collector together in a single maypole, the method can also include changing a carrier gate, such as a bifurcation bar having closed and open gates, from a closed configuration to an open configuration.

The maypole braiding of the first combined yarn on a second side of the collector separate from the may pole braiding of the first combined yarn on the first side of the collector can be concurrent with the maypole braiding of the first combined yarn on the first side of the collector.

Pulling of the first attachment point to the first carrier can include burying the first attachment point in yarn on the first carrier, such as winding the first attachment point into the yarn on a bobbin on the carrier.

The maypole braiding of the first combined yarn on both sides of the collector together in a single maypole can be after the maypole braiding of the first combined yarn on a second side of the collector separate from the maypole braiding of the first combined yarn on a first side of the collector.

The first carrier can be positioned opposite to the second carrier with respect to the braiding machine. The first carrier and the second carrier can rotate around the braiding machine in the same direction.

The method can include loading the braiding machine with a third yarn in a third carrier, and a fourth yarn in a fourth carrier. The method can include attaching the third yarn to the fourth yarn into a second combined yarn. The attaching the third yarn to the fourth yarn can be done at a second attachment point. The method can include pulling the second attachment point to the third carrier. The method can include placing the second combined yarn on the collector. The maypole braiding of the first combined yarn on a first side of the collector can include maypole braiding the first combined yarn with the second combined yarn on the first side of the collector.

The maypole braiding of the first combined yarn on a second side of the collector can include maypole braiding the first combined yarn with the second combined yarn on the second side of the collector separate from the maypole braiding of the first combined yarn on the first side of the collector.

The method can include loading the braiding machine with a third yarn. The maypole braiding of the first combined yarn on a first side of the collector can include maypole braiding the first combined yarn with the third yarn on the first side of the collector.

A method for making a braided textile suture is disclosed. The method can include loading a first yarn on a first carrier and a second yarn in a maypole braiding machine. The method can include attaching the first yarn to the second yarn at an attachment point. The attached first and second yarns can form a combined first yarn. The method can include burying the first attachment point in the first carrier. The method can include operating the maypole braiding machine to produce a bifurcated braid. The bifurcated braid can include the combined first yarn. The method can include then altering the maypole braiding machine to produce a non-bifurcated braid extending continuously from the bifurcated braid. The non-bifurcated braid can include the combined first yarn.

Altering the maypole braiding machine can include moving a gate from a closed configuration to an open configuration, such as sliding a bifurcation bar from a closed configuration to an open configuration.

A braided textile suture is disclosed. The suture can have a closed loop having a convergence point, a tail extending from the convergence point, a first yarn, and a second yarn. The first yarn and second yarn can extend continuously from the tail into a first side of the closed loop. The first and second yarns can extend continuously through the closed loop. The first and second yarns can extend from a second side of the closed loop into and along the tail. The first and second yarns in the tail extending from both sides of the closed loop can be braided in a single maypole in the tail. The first and second yarns can be made from a polymer.

A braided textile suture is disclosed that can have a tail, and a closed loop having a first end and a second end. The first and second ends can converge at the tail. An end of the tail adjacent to the closed loop can be a single maypole braid. The first and second ends of the closed loop can be continuously maypole braided into the tail.

The suture can have yarns continuously extending from the tail into the first end of the closed loop, through the second end of the closed loop and back into the tail. The suture can have yarns in the closed loop and the tail, and more than half of the yarns in the closed loop can extend into the single maypole braid of the tail.

A system and method for making a braided textile is disclosed. The method can include braiding the textile with a braider. The braider can have a first horngear, a second horngear and a first shuttle and a second shuttle. The first horngear can be a horngear immediately adjacent to the second horngear. The first horngear can have a first horngear axis and the second horngear can have a second horngear axis, about which the respective horngears rotate.

The method can include positioning a bifurcation first bar in an obstructing or bifurcating configuration between the first horngear axis and the second horngear axis. The method can include moving the first shuttle when the bifurcation first bar is in the first configuration, and this moving can include the first shuttle moving toward the first horngear along a path of the first horngear, and then against a first side of the bifurcation first bar, and then out of the first horngear away from the second horngear.

The method can also include moving the second shuttle when the bifurcation first bar is in the bifurcating configuration, and this moving can include moving the second shuttle toward the second horngear along a path of the second horngear, then against a second side of the bifurcation first bar, and then out of the second shuttle away from the first horngear.

The method can also include sliding the bifurcation first bar along a longitudinal axis of the bifurcation first bar to an open or non-bifurcating configuration.

The method can also include positioning the bifurcation first bar in the open or non-bifurcating configuration. The method can include moving the first shuttle when the bifurcation first bar is in the open configuration, this moving can include moving the first shuttle along a path of the first horngear toward the second horngear, and then moving the first shuttle immediately to the second horngear.

The method can include moving the second shuttle when the bifurcation first bar is in the open configuration, this moving can include moving the second shuttle along a path of the second horngear toward the first horngear, and then moving the second shuttle immediately to the first horngear.

The method can include positioning the bifurcation first bar in the open configuration. The positioning of the bifurcation first bar can include indexing the position of the bifurcation first bar with at least an indexing pin extending from a braider top plate.

The braider can have a third horngear, a fourth horngear, and a third shuttle. The method can include moving the third shuttle when the bifurcation second bar is in a bifurcating configuration, and this moving can include moving the third shuttle toward the fourth horngear along a path of the third horngear, then against a first side of the bifurcation second bar, and then out of the third shuttle away from the fourth horngear. The method can also include moving the third shuttle when the bifurcation second bar is in an open configuration, this moving can include moving the third shuttle along a path of the third horngear toward the fourth horngear, and then moving the third shuttle immediately to the fourth horngear.

The braider further can include the third horngear, fourth horngear, third shuttle, and a bifurcation second bar having an obstructing or bifurcating configuration and an open or non-bifurcating configuration. The method can include moving the third shuttle when the bifurcation second bar is in the bifurcating configuration, and this moving can include moving the third shuttle toward the fourth horngear along a path of the third horngear, then against a first side of a bifurcation second bar, and then out of the third shuttle away from the fourth horngear. The method can also include moving the third shuttle when the bifurcation second bar is in the open configuration, and this moving can include moving the third shuttle along a path of the third horngear toward the fourth horngear, and then moving the third shuttle immediately to the fourth horngear.

The bifurcation first bar can have a shuttle return track allowing for motion of the shuttles into a first lateral side of the bifurcation first bar and then out of the first lateral side of the bifurcation first bar without exiting a second lateral side of the bifurcation first bar. The bifurcation second bar can have a shuttle return track allowing for motion of the shuttles into a first lateral side of the bifurcation second bar and then out of the first lateral side of the bifurcation second bar without exiting a second lateral side of the bifurcation second bar.

The bifurcation first bar can have a shuttle through track allowing for motion of the shuttles from a first lateral side of the bifurcation first bar to a second lateral side of the bifurcation first bar. The bifurcation second bar can have a shuttle through track allowing for motion of the shuttles from a first lateral side of the bifurcation second bar to a second lateral side of the bifurcation second bar.

Also disclosed is a method for making a braided textile that can include moving carriers with horngears along carrier paths in a braiding machine having an obstructing element having an obstructing configuration and an open or non-obstructing configuration. The method can include dividing the braiding machine with the obstructing element in the obstructing configuration into at least a first portion and a second portion. The method can include obstructing the carrier paths from extending from the first portion into the second portion. The obstructing can include obstructing with the obstructing element in the obstructing configuration. When the carrier paths are obstructed, the carrier paths in the first portion can encircle a first horngear, and the carrier paths in the second portion can encircle a second horngear. The first horngear can be an immediately adjacent horngear to the second horngear.

The method can also include allowing the carrier paths to extend from the first portion into the second portion when the obstructing element is in the open configuration.

The method can include indexing the obstructing element between the obstructing configuration of the obstructing element and the open configuration of the obstructing element.

The method can include moving the obstructing element from the obstructing configuration to the open configuration, and this moving can include sliding the obstructing element within a slot in a carrier top plate of the braiding machine.

The method can include producing a braided textile with a looped end contiguous with a single maypole braid suture tail.

Further disclosed is a method for making a braided textile that can include braiding a textile with a braiding machine. The braiding machine can have a first horngear, a second horngear, and a third horngear on the opposite side of the second horngear from the first horngear, an obstructing bar, and a first carrier. The obstructing bar can have at least an obstructing position and an open or non-obstructing position. The method can include braiding that can include moving the first carrier from the second horngear immediately to the first horngear when the obstructing bar is in the obstructing position. The method can include sliding the obstructing bar along a longitudinal axis of the obstructing bar from the obstructing position to the open position. The braiding can include moving the first carrier from the second horngear immediately to the third horngear when the obstructing bar is in the open position.

The sliding can include indexing the obstruction bar. The indexing of the obstruction bar can include at least sliding an indexing pin in an indexing slot. The sliding can include moving the obstruction bar with an electromechnical actuator. The method can include sliding the obstruction bar from the open position to the obstructing position. The sliding can include translating the obstructing bar within a bar track in a top plate of the braiding machine. The method can include producing a braided textile with a looped end contiguous with a single maypole braid suture tail.

A method of making a braided textile having a distal end including a closed loop of an interbraided braid and a proximal end including a tail is disclosed. The method can include setting a braiding machine to a bifurcation braiding configuration. The method can include selecting a holder. The method can include placing one yarn end in a carrier on one side of the machine and placing a second yarn end in a second carrier on an opposing side of the machine. The carriers can move in the same direction (i.e., clockwise or counterclockwise). The method can include tying the yarn ends together. The method can include optionally repeating placing yarn on opposing sides of the machine and tying the yarn ends together, for example, from <NUM> to <NUM> times. The method can include braiding in a bifurcation braiding configuration until the braided braid is long enough to encircle the holder. The method can include stopping the braiding machine and switching the braiding machine to a maypole braiding configuration. The method can include then braiding in a maypole braiding configuration until a desired length of a tail of the braided textile has been formed.

The holder may be, for example, an S-hook style mandrel. The closed-loop of the braided textile can be braided around the holder. The outer diameter of the holder can be or correlate with the final inner diameter of the closed loop.

A method of weaving or braiding the braided textile is disclosed. The method can include that braider bobbins can be wound with a desired size of yarn and pulled into each of the carriers on the machine. The braider can be set to a bifurcation braiding configuration and the carriers can be evenly split with half of the carriers on each side of the machine. A yarn from a carrier on each side can be tied together using a standard knot. The carrier yarns that are tied together can be moving in the same radial direction on the machine. Each yarn bundle can be placed on the collector hook. The braiding machine, for example rotating of the horngears, can then be started.

The diameter of the closed loop of the braided textile can be defined by the operators input for pick count (i.e., a measure of density of a braid) in bifurcation braiding configuration. When the desired pick count is reached, the machine can be converted over to standard single maypole braiding. This is controlled by moving electromechanical or pneumatically actuated gates, for example to slide the bifurcation bars, in the top plate and/or within the braider bed. The braiding machine can then begin braiding the tail section of the braided textile with the length being defined by the HM I setting ("human machine interface," for example performed via a programmable linear controller) for picks for the tail feature. When the final pick count is reached, the machine can turn off automatically and can position the carriers in the bifurcation position. The operator can then resets the machine by cutting two yarn ends and tying them together. This process can be repeated until all the carrier yarns are tied off. The braider can be a <NUM> carrier braiding machine with <NUM> carriers being utilized.

A braiding machine or braider <NUM> and a method of making a braided textile, such as a suture, having a distal end and a proximal end using the braiding machine are disclosed.

<FIG> illustrate that the braider <NUM> can have a braider top plate <NUM> with an obstructing or bifurcation rod or bar <NUM>. The bifurcation bar <NUM> can have a bifurcation bar longitudinal axis <NUM> across the braider top plate <NUM> that can divide the braider top plate <NUM> into a first portion <NUM> and a second portion <NUM>. More than one bifurcation bar can be used to divide the braider top plate into more than two portions. The braider <NUM> can have one or more horngears <NUM>, such as first through eighth horngears 103a-<NUM>. The horngears <NUM> can be below the top plate <NUM>. Each horngear <NUM> can rotate around a respective horngear axis <NUM>, such as first and second horngear axes 107a and 107b.

The braider <NUM> can have one or more carriers <NUM>, such as first through sixteenth carriers 200a-200p. The braiders <NUM> can each carry one or more yarns, for example on a spool or bobbin rotatably carried on a bobbin axle <NUM> on the carrier <NUM>. The yarns can be braided into the braided textile.

The top plate <NUM> can have a carrier tracks <NUM>, such as intersecting first and second carrier tracks 132a and 132b. The carriers <NUM> can slide through the carrier tracks <NUM>. The carriers <NUM> can be placed in the carrier tracks <NUM> and slide in a <NUM>-over-<NUM> configuration (i.e., a carriers alternating passing each other in opposite directions on the carrier tracks), <NUM>-over-<NUM>-by-<NUM> (also known as <NUM>-over-<NUM>) configuration, <NUM>-over-<NUM> configuration (i.e., pairs of carriers alternating passing each other in opposite directions on the carrier tracks), or combinations thereof. The carrier tracks <NUM> encircling each horngear <NUM> can be horngear paths, for example first through eighth horngear paths 134a-h for the first through eighth horngears 103a-h, respectively.

Each carrier <NUM> can be pushed and driven through the carrier track <NUM> by the closest horngear <NUM>.

The bifurcation bar <NUM> can have one or more switching gates <NUM> and transfer gates <NUM>. The gates can have track through which the carriers <NUM> can slide. The transfer gates <NUM> can allow the carrier <NUM> to pass from a first lateral side of the bifurcation bar <NUM> to a second lateral side of the bifurcation bar <NUM>. The switching gates <NUM> can return the carrier <NUM> from the same lateral side of the bifurcation bar <NUM> from which the carrier <NUM> entered the switching gate <NUM>.

The top plate <NUM> can have one or more loading slots <NUM> and loading locks <NUM> in the loading slots <NUM>. The loading locks <NUM> can be attached and detached from the braider <NUM> by loading lock bolts <NUM>. When the loading slots <NUM> are open (e.g., the loading locks <NUM> are not in the loading slots), the carriers <NUM> can be loaded into and/or unloaded from the carrier tracks <NUM>.

The top plate <NUM> can be attached to a chassis or frame of the braider <NUM> with top plate mounting bolts <NUM>.

The braider <NUM> can have embedded gates <NUM>. The embedded gates <NUM> can be inserted into holes or divots in the top of the top plate <NUM> and bolted to the top plate <NUM>. The top surface of the embedded gates <NUM> can be flush with the top surface of the top plate <NUM>. The embedded gates <NUM> can have tracks aligned with the carrier tracks <NUM> to act as transfer gates and allow the carriers to pass through the embedded gates <NUM>. The embedded gates <NUM> can be rotated (e.g., at <NUM> degrees) compared to shown in <FIG> to block the path of the carrier tracks <NUM> and obstruct the path of the carriers <NUM>, for example blocking the carriers <NUM> and acting as switching gates.

<FIG> illustrates that the bifurcation bar <NUM> can be in a closed, bifurcated, obstructed or return configuration or position. Sliding the bifurcation bar <NUM> in a first direction <NUM> in the bifurcation bar track <NUM> along the bifurcation bar longitudinal axis <NUM> can translate the bifurcation bar from an open configuration to the obstructed configuration.

<FIG> illustrates that the bifurcation bar <NUM> can be in the open, transfer, or unobstructed configuration. For example, the bifurcation bar <NUM> can be slid in a second direction <NUM> in the bifurcation bar track <NUM> along the bifurcation bar longitudinal axis <NUM>.

The braider <NUM> can have an indexing pin <NUM>. The indexing pin <NUM> can be fixed with respect to the top plate <NUM>. The bifurcation bar <NUM> can have an indexing slot <NUM> along a length of the bifurcation bar longitudinal axis <NUM>. The indexing pin <NUM> can extend through the indexing lot <NUM>. The bifurcation bar <NUM> can be slidable along the indexing pin <NUM> in the first direction <NUM> and the second direction <NUM>. When the indexing pin <NUM> is at a first terminal longitudinal end of the indexing slot, the bifurcation bar <NUM> can be in the closed configuration. When the indexing pin <NUM> is at a second terminal longitudinal end of the indexing slot, the bifurcation bar <NUM> can be in the open configuration.

<FIG> illustrate that when the bifurcation bar <NUM> is in the closed configuration, a first carrier 200a can move along the first horngear path <NUM> (or first carrier path) in a first carrier translation first direction <NUM> toward the second horngear 103b and then can move against a first side <NUM> of the bifurcation bar <NUM> along a first bifurcated path <NUM> (or channel or shuttle track) and then back on the first horngear path <NUM> in a first carrier translation second direction <NUM> away from the second horngear 103b. Similarly, a second carrier 200b and a second shuttle <NUM> coupled to the second carrier 200b can move along the second horngear path 134b (or second carrier path) in a second carrier translation first direction <NUM> toward the first horngear 103a and then move against a second side <NUM> of the bifurcation bar <NUM> along a second bifurcated path <NUM> (or channel or shuttle track) and then back on the second horngear path 134b in a second carrier translation second direction <NUM> away from the first horngear 103a.

<FIG> illustrate that when the braider <NUM> is in the open configuration, the first carrier 200a can move along the first horngear path <NUM> in the first carrier translation first direction <NUM> toward the second horngear 103b and then move immediate to the second horngear 103b through a first non-bifurcated channel <NUM> (or shuttle track) and move into the second horngear path 134b in a first carrier translation third direction <NUM> further away from the first horngear 103a. Similarly, the second carrier 200b and the second shuttle <NUM> coupled to the second carrier 200b can move along the second horngear 134b (or second carrier path) in a second carrier translation direction <NUM> toward the first horngear and then move immediately to the first horngear 103a through the first non-bifurcated channel <NUM> and move into the first horngear path <NUM> in a second carrier translation third direction <NUM> further away from the second horngear 103b.

<FIG> and <FIG> illustrate that the horngears <NUM> can be above the top plate <NUM>. The carrier <NUM> can have or be attached to a carrier base, carrier foot, or shuttle <NUM> extending from the remainder of the carrier <NUM> in the direction of the horngear <NUM>. The horngear <NUM> can have one or more horngear notches <NUM> (e.g., four, as shown, at <NUM>° to each other with respect to the horngear axis). The shuttle <NUM> can slidably engage into the horngear notch <NUM>. When the horngear <NUM> rotates about the horngear axis, the horngear notch <NUM> can transmit rotational energy to the shuttle, for example, rotating the carrier around the horngear axis until the shuttle reaches an empty horngear notch of an adjacent horngear, at which point the shuttle can transfer to the adjacent horngear if otherwise unimpeded, such as by a closed switching gate on the bifurcation bar <NUM>.

The first horngear 103a can be coupled to the first carrier 200a and fifth carrier 200e via the first shuttle <NUM> and fifth shuttle <NUM>, respectively. The second horngear 103b can be coupled to the second carrier 200b and sixth carrier 200f via the second shuttle <NUM> and the sixth shuttle <NUM>, respectively. The third horngear 103c can be coupled to a third carrier 200c and a seventh carrier <NUM> via a third shuttle <NUM> and seventh shuttle <NUM>, respectively. The fourth horngear 103d can be coupled to a fourth carrier 200d and an eighth carrier <NUM> via a fourth shuttle <NUM> and an eighth shuttle <NUM>, respectively. The fifth horngear 103e can be coupled to a ninth carrier 200i and an eleventh carrier <NUM> via ninth shuttle <NUM> and an eleventh shuttle <NUM>, respectively. The sixth horngear <NUM> can be coupled to a tenth carrier 200j and a twelfth carrier <NUM> via a tenth shuttle <NUM> and a twelfth shuttle <NUM>, respectively. The seventh horngear <NUM> can be coupled to a thirteenth carrier <NUM> and fifteenth carrier 200o via a thirteenth shuttle <NUM> and a fifteenth shuttle <NUM>, respectively. The eighth horngear <NUM> can be coupled to a fourteenth carrier <NUM> and a sixteenth carrier 200p via a fourteenth shuttle <NUM> and a sixteenth shuttle <NUM>.

<FIG> further illustrates that the braider <NUM> can have the first bifurcation bar <NUM> and a second bifurcation bar <NUM>. <FIG> illustrates that the second bifurcation bar <NUM> can slide within a bifurcation second bar track <NUM>, transitioning between the closed configuration and the open configuration.

<FIG> further illustrates that when the second bifurcation bar <NUM> is in the open configuration, a second non-bifurcated channel <NUM> can align with the third horngear path 134c and the fourth horngear path <NUM>. Sliding the second bifurcation bar <NUM> in the second direction <NUM> can transition the second bifurcation bar <NUM> from the open configuration (<FIG>) to the closed configuration (<FIG> further illustrates that when the second bifurcation bar <NUM> is in the closed configuration, a third bifurcated channel <NUM> and a fourth bifurcated channel <NUM> of the second bifurcation bar <NUM> can align with the third horngear path 134c and the fourth horngear path <NUM>, respectively.

<FIG> and <FIG> illustrate that the carriers can be coupled to plates that turn with the carriers via the horngears allowing the carriers to move from one horngear to another. By way of example, <FIG> illustrates that the eighth plate <NUM> can comprise a first slot 327a, a second slot 327b, a third slot 327c, and a fourth slot 327d wherein the fourteenth carrier 200n and the sixteenth carrier 200p can sit in the second slot 327b and the fourth slot 327d. The eighth plate <NUM> can turn to a position wherein fourth slot 327d is aligned with the fourth horngear path <NUM> wherein the sixteenth carrier 200p can leave the fourth slot 327d and move into the fourth horngear 103d. The other plates on the braider <NUM> can turn in a similar fashion such that the carriers sitting in their corresponding slots can move into adjacent horngears once properly aligned. The first plate <NUM> can be coupled to the first horngear 103a, the second plate <NUM> can be coupled to the second horngear 103b, the third plate <NUM> can be coupled to the third horngear 103c, the fourth plate <NUM> can be coupled to the fourth horngear 103d, the fifth plate <NUM> can be coupled to the fifth horngear 103e, the sixth plate <NUM> can be coupled to the sixth horngear 103f, the seventh plate <NUM> can be coupled to the seventh horngear <NUM>, and the eighth plate <NUM> can be coupled to the eighth horngear <NUM>.

<FIG> illustrate that the first bifurcated channel <NUM> and the second bifurcated channel <NUM> of the first bifurcation bar <NUM> can be separated by a first bifurcating divider, diverter or guide <NUM>, and the third bifurcated channel <NUM> and the fourth bifurcated channel <NUM> of the second bifurcation bar <NUM> can be separated by a second bifurcating divider, diverter or guide <NUM>. The second bifurcation bar <NUM> can comprise a first side <NUM> of the second bifurcation bar <NUM> against which the third carrier 200c and the third shuttle <NUM> can move against and a second side <NUM> of the second bifurcation bar <NUM> against which the fourth carrier 200d and the fourth shuttle <NUM> can move against.

<FIG> illustrates that the carrier <NUM> can have a spool or bobbin holder or axle <NUM>. The carrier <NUM> can have a compensator arm <NUM>. The compensator arm <NUM> can be rotatably and elastically (e.g., with a spring) attached to the body of the carrier <NUM>, for example rotating in and out relative to the remainder of the carrier <NUM>, and/or slidably (i.e., translatably) and elastically attached to the body of the carrier <NUM>, for example sliding up and down relative to the remainder of the carrier <NUM>. The compensator arm <NUM> can be a mechanical capacitor for the speed of yarn being delivered by the carrier <NUM>. For example, the compensator arm <NUM> can rotate up to maintain tension when yarn being delivered from the carrier <NUM> is increasing in speed, and can rotate down to maintain tension when yarn being delivered from the carrier <NUM> is decreasing in speed. The carriers <NUM> can have a yarn guide <NUM> extending from the top distal end of the carrier <NUM>. The yarn guide can secure a yarn from a spool that can be held by the spool holder <NUM>.

<FIG> illustrate that the carriers <NUM> can have carrier first and second feet or track interfaces <NUM> and <NUM>. The carrier track interfaces <NUM> and <NUM> can extend into the carrier track <NUM> and slidably guide or steer the carrier <NUM> through the carrier track <NUM>. The carrier track interfaces <NUM> and <NUM> can be rotatably connected to the remainder of the carrier <NUM>. The carriers <NUM> can each have a carrier base <NUM> that can be configured to engage and disengage with the horngear notches <NUM>. The shuttle <NUM> can include the carrier base <NUM> and/or the carrier track interfaces <NUM> and <NUM>.

<FIG> illustrates that the bifurcation bar <NUM> and/or the loading locks <NUM> can extend to, and/or past, and/or be flush with the terminal radial peripheral surface of the top plate <NUM>.

<FIG> illustrates that a first braider 100a may be adjacent to a second braider 100b on the same chassis as the first braider 100a. The carriers <NUM> can be positioned in pairs opposite to each other (e.g., the opposite carrier can be a complementary carrier) with respect to the braider <NUM>. For example, the first carrier 200a can be opposite from and complementary, as shown in <FIG>, to the eighth carrier <NUM>. Each individual carrier <NUM> and its complemental carrier <NUM> can move along the carrier path, channel or track <NUM> in the same direction (e.g., both clockwise or both counter clockwise).

The top plate <NUM> can have stationary horngear plates <NUM>, such as first through eighth horngear plates 818a-<NUM>, that can cover the respective horngears <NUM>.

<FIG> and <FIG> illustrates that a braiding machine control system <NUM> can have first and second braiders 100a and 100b and a controller <NUM>, such as a networked computer having a processor and memory. Separate coupled pairs of a bifurcation rod extensions <NUM> and a bifurcation rod electromechanical actuator or solenoid <NUM> can each be coupled to the first and second braiders 100a and 100b. The controller <NUM> can instruct the solenoid <NUM> to push the bifurcation rod extension <NUM>, for example, to slide the bifurcation rod <NUM> into the open or closed configuration. The braider machine control system <NUM> can have a wired connection <NUM> to connect the braiding controller <NUM> to the solenoids <NUM>.

The controller <NUM> can control and/or monitor the speed of rotation of the horngears <NUM>.

The system <NUM> can have a vertical support <NUM>. The system <NUM> can have an elevating mount <NUM>, for example, attached to and vertically slidable with respect to the vertical support <NUM>. The elevating mount <NUM> can be attached to an elevating pulley <NUM> and/or collector hook <NUM> and/or take up mandrel. The vertical support <NUM> can have an elevating motor controlled by the braiding controller <NUM>. The controller <NUM> can control the elevating motor to elevate elevating mount, and/or the elevating pulley <NUM> and/or collector hook <NUM> and/or take up mandrel, and, for example, the elevating rate can depend on the speed of the horngears <NUM>.

<FIG> illustrates that an elevating pulley <NUM> can be secured above a take up mandrel <NUM> wherein a braided suture leader <NUM> can be wound around the take up mandrel <NUM> in an evenly distributed fashion <NUM> and up around the elevating pulley <NUM> between copper ties <NUM> that secure the elevating leader <NUM> and back down and tied to a collector hook <NUM> by an elevating leader knot <NUM>.

<FIG> illustrates the elevating leader <NUM> can be tied around a first end of an S-shaped collector hook <NUM> at an elevating leader knot <NUM>. The braided textile can be braided around the second end of the S-shaped collector hook <NUM>.

<FIG> illustrates that a ruler <NUM> can be used to measure a distance <NUM> between the collector hook <NUM> to a top <NUM> of a carrier, such as the first carrier <NUM> on the first braider <NUM>, for example.

<FIG> illustrate that an attachment, such as double-loop knot <NUM>, between two yarns from opposite carriers can be formed. The attachments can be formed by any method including tying a knot, ultrasonic welding, epoxying or gluing with a liquid, clipping with a clipping element, applying shrink tubing, or combinations thereof. For example, a first yarn <NUM> from the first carrier 200a can be grabbed along with a second yarn <NUM> from the eighth carrier <NUM>. Then the first yarn <NUM> and the second yarn <NUM> can be crossed at a crossing point <NUM> and the first yarn <NUM> and second yarn <NUM> can be wrapped <NUM> around a first holder, such as a finger. Then, the first yarn <NUM> and the second yarn <NUM> can be held down <NUM> by a second holder, such as a thumb. Then the first yarn <NUM> and the second yarn <NUM> can be pulled through a loop <NUM>. Then a knot <NUM> is formed when the first yarn <NUM> and the second yarn <NUM> can be pulled. The method shown in <FIG> can be repeated such that the double-loop knot <NUM> can be formed and then tails <NUM> of the first yarn <NUM> and the second yarn <NUM> can be cut.

<FIG> illustrates that the first yarn <NUM> and the second yarn <NUM> can be tied at the double-loop knot <NUM>. The first carrier 200a holding the first yarn <NUM> and the eighth carrier <NUM> holding the second yarn <NUM> can be on opposite sides of the bifurcation bar <NUM> coupled to braider top plate <NUM>. The bifurcation bar <NUM> can sit on top of the braider top plate <NUM> and block two horngears such that only six out of the eight horngears are operable when the bifurcation bar <NUM> is coupled to the braider top plate <NUM>.

<FIG> illustrates that a spool <NUM> coupled to the spool holder <NUM> of the first carrier 200a can be reeled back, as shown by arrow <NUM>. The tied together first and second yarns <NUM> and <NUM> can then be pulled toward and into the spool <NUM>, as shown by arrows <NUM>. The double-loop knot <NUM> can then be so deeply buried into the remaining yarn on the spool <NUM> that when the braider <NUM> completes the desired braided textile, the double-loop knot <NUM> can remain in the spool <NUM>. For example, after the double-loop knot <NUM> contacts the remaining yarn in the spool <NUM>, the spool can be rotated, for example, greater than about <NUM> revolutions, more narrowly between about <NUM> revolutions and about <NUM>,<NUM> revolutions, more narrowly from about <NUM> revolutions to about <NUM>,<NUM> revolutions, to pull and embed the knot <NUM> into the yarn of the yarn already on the spool <NUM>. Also for example, the double-loop knot <NUM> can be pulled away from the collector hook <NUM> and/or past the initial contact with the yarn already wound to the spool <NUM> for a length equal to or greater than the lay length of the construct or desired braided textile multiplied by a longitudinal length of the desired braided textile. (The frayed cut ends of the excess yarn from the knot can be seen in <FIG>, helping to visualize the location of the knot <NUM>.

<FIG> and <FIG> illustrate that a first tied yarn <NUM> can be formed by tying the first yarn <NUM> from the first carrier 200a with the second yarn <NUM> from the eighth carrier <NUM>. A second tied yarn <NUM> can be formed the same way from yarn from the second carrier 200b and the seventh carrier <NUM> (e.g., the complimentary carrier to the second carrier), and for the yarn from the remaining complementary carrier pairs, resulting in a third tied yarn <NUM> and a fourth tied yarn <NUM>, respectively. After their respective knots or other attachment points have been buried into their respective spools, as shown and described in <FIG> and above, the first, second, third and fourth tied yarns <NUM>, <NUM>, <NUM>, and <NUM> can be looped onto the collector hook <NUM> one-by-one, for example as each one is tied, or concurrently.

<FIG> and <FIG> illustrate that a braided suture loop <NUM> can then be braided when the bifurcation bar(s) <NUM> is(are) in a bifurcated configuration. The braider <NUM> can produce two maypole braids, one for each side of the braided textile extending from the collector hook <NUM>. The first tied yarn <NUM> can have a first tied yarn first end <NUM> and a first tied yarn second end <NUM>. The second tied yarn <NUM> can have a second tied yarn first end <NUM> and a second tied yarn second end <NUM>. The third tied yarn <NUM> can have a third tied yarn first end <NUM> and a third tied yarn second end <NUM>. The fourth tied yarn <NUM> can have a fourth tied yarn first end <NUM> and fourth tied yarn second end <NUM>.

The open braided loop <NUM> can be formed by braiding the first tied yarn <NUM>, the second tied yarn <NUM>, the third tied yarn <NUM>, and the fourth tired yarn <NUM> when the bifurcation bar(s) <NUM> is(are) in a bifurcated configuration. The first, second, third and fourth tied yarn first ends <NUM>, <NUM>, <NUM>, and <NUM> can braid amongst one another forming a four-strand braid on a first side of the pre-closing braided loop <NUM> extending from the hook <NUM>. The first, second, third and fourth tied yarn second ends <NUM>, <NUM>, <NUM>, and <NUM> can braid amongst one another forming a four-strand braid on a second side of the pre-closing braided loop <NUM> extending from the hook <NUM>.

<FIG> and <FIG> illustrate that after the bifurcation bar(s) <NUM> is(are) moved to an open configuration, a braided suture closed loop <NUM> braided around the collector hook <NUM> can then be formed. A single maypole braid suture tail <NUM> extending from a converge or bifurcation end point <NUM> at the closure point of the closed-loop can be braided. The first, second, third, and fourth tied yarn first ends <NUM>, <NUM>, <NUM>, <NUM>, and the first, second, third and fourth tied yarn second ends <NUM>, <NUM>, <NUM>, and <NUM> can braid amongst one another to form the single maypole braid suture tail <NUM>.

<FIG>, <FIG>, and <FIG> illustrate that both sides or ends of the loop <NUM> and the respective yarns can converge continuously at the convergence, divergence, or bifurcation end point <NUM> and extend to the tail <NUM>. The loop <NUM> is an interbraided braid. All, or at least more than half, of the yarns on both side of the loop <NUM> can extend continuously into the single maypole braid of the tail <NUM>. All, or at least more than half, of the yarns of the single maypole braid of the tail <NUM> can extend continuously into the loop <NUM>. The resulting braided textile suture or construct <NUM> can have a completely closed loop <NUM> and tail <NUM> having a shear cut tail terminal end <NUM>.

The distal end of the braided textile can have a closed loop <NUM> of an interbraided braid, and the proximal end having the tail <NUM>. Once removed from the collector hook <NUM>, the hole in the lasso-shaped closed loop can be where the collector hook <NUM> was positioned during the braiding of the braided textile.

<FIG> illustrate that construct <NUM> can have reinforcement grommet <NUM> in the closed loop <NUM>. The reinforcement grommet can be made from any of the materials listed elsewhere herein as well as plastic, rubber, or combinations thereof. The grommet <NUM> can be rigid or flexible. The grommet <NUM> can be elastic and resilient. The grommet <NUM> can be coated with a friction reducing material such as PTFE. The grommet <NUM> can be circular, oval, octagonal, square, rectangular, triangular, teardrop-shaped (e.g., the shape of the area inside of the closed loop <NUM>), or combinations thereof. The grommet can be fixed in the closed loop <NUM> or can rotate compared to the closed loop <NUM> with respect to an axis passing through and perpendicular to a plane of the opening in the closed loop <NUM>.

<FIG> illustrates that the grommet <NUM> can have a recessed grommet track <NUM>, along the outside circumference of the grommet <NUM>. The length of the construct <NUM> of most or all of the closed loop <NUM> can seat in the grommet track <NUM>. The grommet <NUM> can have radially extending or raised grommet sidewalls <NUM> on one or both lateral sides of the grommet track <NUM>.

<FIG> illustrates that the construct <NUM> can have a first closed loop 1800a at the terminal distal end of the construct <NUM>. The construct <NUM> can have a second closed loop 2800b spaced longitudinally at a distance from a first bifurcation end point 1804a with a length of a single braid of the construct with yarns that can be continuously extending from the first closed loop 1800a to and through the second closed loop 1800b. Proximal to the second bifurcation point 1804b of the second closed loop 2800b, the single braid tail <NUM> can split at a tail split point <NUM> into a first tail 1802a and a second tail 1802b. The first and second tails 1802a and 1802b can each have half the yarns continuously extending from the single braid tail <NUM>. The first and second tails 1802a and 1802b can be made using the method to form the closed loops <NUM>, but instead of moving the bifurcation bar <NUM> into an open configuration after the splitting of the tail <NUM>, the proximal terminal ends of the first and second tails 1802a and 1802b can be shear cut from the braiding machine.

<FIG> illustrates that the construct <NUM> can have additional closed loops <NUM> between the first closed loop 1800a at the distal terminal end of the construct <NUM> and the tail <NUM> or proximal terminal end of the construct, such as the second through fourth closed loops 1800b-1800d. Some or all of the closed loops <NUM> can have semicircular shapes, such as the second through fourth closed loops 1800b-1800d. The semicircular closed loops can be formed by running the horngears <NUM> in a first portion <NUM> of the braiding machine <NUM> at a faster speed than the horngears <NUM> in a second portion <NUM> of the braiding machine <NUM> when the bifurcation bar <NUM> is in a closed or obstructing configuration.

<FIG> illustrates that the construct <NUM> can have two or more closed loops <NUM> extending laterally from a intermediate length or loop bridge <NUM> of the construct. The closed loops <NUM> can extend from the loop bridges <NUM> in pairs symmetric with respect to the longitudinal axis of the construct. For example, the second closed loop 1800b can extend angularly or diametrically opposite from the fifth closed loop 1800e with respect to the loop bridge <NUM>. The pair of closed loops <NUM> can be at the same, overlapping, or non-overlapping longitudinal lengths along the construct <NUM>. The construct <NUM> can have three pairs of closed loops <NUM> extending from the loop bridges <NUM>, such as the second and fifth loops 1800b and 1800e, the third and sixth loops 1800c and <NUM> f, and the fourth and seventh loops 1800d and <NUM>. This construct <NUM> can be made using the method disclosed herein and by splitting the braider <NUM> into three portions with bifurcation bars <NUM>, and operating the horngears <NUM> in two of the portions at a faster speed than the third portion. The yarns in the single braid lengths of the construct <NUM> can extend continuously through the closed loops and loop bridges.

<FIG> illustrates that the construct <NUM> can have closed loops 1800a-1800c than can each extend from a separate braid neck <NUM>. The braid necks <NUM> can converge into a single (as shown) or multiple neck convergence points <NUM>. The yarns in the tail can extend continuously through the necks <NUM> and closed loops <NUM>.

The braid may be made of yarn, such as natural materials such as silk and cotton, synthetic materials such as polymers, for example polyethylene, polyethylene terephthalate (PET), ultra high molecular weight polyethylene (UHMWPE), polytetrafluoroethylene (PTFE), or other biocompatible polymer, biologically incompatible yarn such as cotton, metal (e.g., gold, platinum, nickel, tin, nitinol, cobalt, chromium, stainless steel), polyester, nitinol, polypropylene, or combinations thereof.

The resulting prosthetic braided textile may be coated or otherwise treated with a suitable biocompatible material to permit enhanced acceptance by and use in the body. The yarns may be resorbable, nonabsorbable, or a combination thereof.

The braided textile may be braided to be a length generally known for use with medical devices or implantation in an adult or infant human. The braid at the proximal end may have the same diameter or a different diameter than the braid on the closed loop. The braided textile may be any shape and braided according to any known pattern for making a braided textile, for example round, flat, or combinations thereof. The braid may be braided with a marker, such as a colored yarn, braided therethrough. One or more of the yarns may be a different material or yarn than the remainder of the yarns.

The braided textile may have more than one closed loop at the distal end. For example, two, three, four, five or more closed loops may be individually braided at the distal end and then all braided together to form the tail of the braided textile.

The braided textile can be made without burying the knots within the construct (i.e., the braided textile itself). The braided textile can have a consistent strength through the entire structure, such as throughout the length of the textile from the loop to the tail. The tensile strength of each end of the loop can be about <NUM>% of the tensile strength of the tail. The loop can have symmetric geometry about a longitudinal bisecting plane <NUM>. For example, the textile can have a substantially constant tensile strength in the loop section of the textile.

Braids can be made on any conventional braiding machines that can be purchased from a supplier, such as Herzog, Ratera and HC Machines. Any of these machines can be used as a starting platform for a custom machine to make the braided textiles disclosed herein. A standard maypole braiding machine can allow individual carriers, individual yarn shuttles, to radially wrap yarns in both the clockwise and counterclockwise direction. The yarns in the final braided product can be braided together as the carriers on the braiding machine are on crossing elliptical paths. The paths of the yarn carriers can be manipulated during the braiding process. The carrier paths can be guided by using diverters within the base plate that are controlled by a computer. The braiding machine carriers follow one of two paths to make each part of the braided textile. That is, a standard maypole braiding configuration to make the single braided braid of the tail section, and a bifurcation braiding configuration to braid the closed loop. The proposed custom designed braiding machine would allow the operator to switch back and forth between standard maypole and bifurcation configuration. The operator can adjust input values into the human machine interface (HMI) on the braiding machine that would allow for precise control over the diameter of the closed loop and the length of the tail. The braiding disclosed herein can be maypole braiding, non-maypole braiding, or combinations thereof. The resulting braided textile suture or construct can have no shear cut ends except at the terminal end of the tail away from the closed loop.

Elements of the apparatuses and methods disclosed in <CIT>, <CIT>, and<CIT> can be used in combination with any of the apparatuses and methods disclosed herein. The suture leader <NUM> can be formed into a flat tape. The term "bifurcation" as used herein can refer to true bifurcation and/or production of two separate maypole braids adjacent to each other (e.g., and then optionally coalescing the two braids back into a single construct or braid).

Claim 1:
A braided construct (<NUM>), comprising:
a) yarns (<NUM>, <NUM>, <NUM>, <NUM>) that are braided to form a first side of a first closed loop (<NUM>) and a second side of the first closed loop (<NUM>), and
b) wherein the braided first and second sides of the first closed loop (<NUM>) converge at a first convergence point (<NUM>) where the yarns (<NUM>, <NUM>, <NUM>, <NUM>) from the first and second sides are braided amongst one another into a single braid forming a first tail (<NUM>) so that the yarns (<NUM>, <NUM>, <NUM>, <NUM>) continuously extend from the first tail (<NUM>) into the first convergence point (<NUM>) and then into the first side of the first closed loop (<NUM>) and then into the second side of the first closed loop (<NUM>) and then back to the convergence point (<NUM>) and into the first tail (<NUM>), characterised by four yarns (<NUM>, <NUM>, <NUM>, <NUM>) that are braided amongst one another to form a four-strand braid on a first side of a first closed loop (<NUM>) and a four-strand braid on a second side of the first closed loop (<NUM>).