Tissue repair device and apparatus and method for fabricating same

Abstract

A mold for fabricating a device for repairing torn tissue or muscle such as the meniscus of the knee is provided. The mold includes a mold cavity adapted to receive molten material. The mold cavity has an inlet channel, a first portion, a second portion, and a first channel extending between the first and second portions. The inlet channel communicates with the first and second portions and is spaced from the first channel such that the molten material must flow from the inlet channel through the first portion or second portion before communicating with the first channel. The first channel is dimensioned to receive a first component such that the flow of molten material from the first and/or second portions into the first channel is substantially prevented when the first component is received in the first channel.

1 . A mold comprising:
 a mold cavity adapted to receive molten material, the mold cavity including an inlet channel, a first portion, a second portion, and a first channel extending between the first and second portions, the inlet channel communicating with the first and second portions and being spaced from the first channel such that the molten material must flow from the inlet channel through the first portion or second portion before communicating with the first channel,   wherein the first channel is dimensioned to receive a first component such that the flow of molten material from the first and/or second portions into the first channel is substantially prevented when the first component is received in the first channel.   
     
     
         2 . The mold of  claim 1 , wherein the first and second portions each have a proximal end, sidewalls, and a distal end having a sharp, pointed tip. 
     
     
         3 . The mold of  claim 2 , wherein the first channel extends between the proximal ends of the first and second portions. 
     
     
         4 . The mold of  claim 3 , wherein the first channel further extends through the first and second portions and out the distal end of the first and second portions, offset from the tip. 
     
     
         5 . The mold of  claim 4 , further comprising a plurality of inlet channels and a plurality of first and second portions configured in a repeating series such that the proximal end of each of the first portions is proximate to a proximal end of one of the second portions and the distal end of each of the first portions is proximate to the distal end of one of the second portions, wherein the first channel connects the plurality of first and second portions by extending between the proximal ends of the first and second portions and the distal ends of the first and second portions. 
     
     
         6 . The mold of  claim 2 , wherein the sidewalls of the first and second portions form a plurality of outwardly projecting barbs. 
     
     
         7 . The mold of  claim 1 , wherein the overall length of the mold cavity is about 0.120 inches to about 6 inches. 
     
     
         8 . The mold of  claim 1 , wherein the first portion and the second portion are each about 0.04 inches to about 2 inches in length. 
     
     
         9 . The mold of  claim 1 , wherein the first channel is about 0.04 inches to about 2 inches in length. 
     
     
         10 . The mold of  claim 1 , wherein the mold cavity is formed from mold halves including a mold portion having projecting pegs and a countermold portion having recesses, wherein the countermold portion is formed substantially as a mirror image to the mold portion in a way that the recesses in the countermold portion are at a location corresponding to the projecting pegs in the mold portion so that the mold cavity is formed by fitting the mold and countermold portions together. 
     
     
         11 . The mold of  claim 10 , wherein the inlet channel, the first portion, the second portion, and the first channel of the mold and countermold portions are substantially symmetrical. 
     
     
         12 . The mold of  claim 1 , further comprising a heating/cooling source to control heat application to the mold and prevent damage or changes to the first component. 
     
     
         13 . The mold of  claim 1 , wherein the molten material is introduced under pressure into the mold cavity by a process selected from the group consisting of injection molding and compression molding.