Braiding machine for producing three-dimensional braided matrices

Abstract

A braiding machine for that produces three-dimensional braided matrices with a suitable pore structure for even and random distribution and in-growth of cells for tissue growth and repair is described herein. Methods for making three-dimensional matrices with controlled thicknesses and porosity and the resulting matrices are also described. The machine contains curved arches that hold the plurality of carriers. At least two of the arches are moveable in a side-to-side direction. Additionally, a controlled pushing mechanism pushes the carriers up and down the slots in the arches. These motions allow one to form three-dimensional braided matrices that provide sufficient porosity and mechanical support for tissue growth and repair in a variety of sites in the body.

We claim: 
     
         1 . A machine for producing a three-dimensional matrix with controlled porosity comprising
 (a) a frame,   (b) at least four carrier arches stacked in a linear manner and attached to the frame, wherein the two outer arches are fixed and the inner arches are moveable in sideways directions relative to the frame, and wherein each arch comprises a plurality of slots and spacers that alternate along the length of each arch,   (c) a plurality of moveable carriers, wherein each slot is configured to receive a carrier,   (d) a carrier pushing mechanism configured to push a carrier in a front to back direction relative to the frame.   
     
     
         2 . The machine of  claim 1 , wherein the arches are aligned such that the slots on each arch align with corresponding slots in the proximal arch forming rows of slots. 
     
     
         3 . The machine of  claim 1 , wherein the yarns begin forming the braided matrix at a braid point, wherein the lengths from the tip of each carrier to the braid point are within ±10% of each other, preferably within ±5% of each other, more preferably within ±2% of each other. 
     
     
         4 . The machine of  claim 1 , wherein the total number of arches is 4, 5, 6, 7, 8, 9, or 10 arches. 
     
     
         5 . The machine of  claim 1 , wherein the carrier pushing mechanism comprises a carrier pusher drive system and a plurality of pushers, wherein each pusher aligns with one row of slots. 
     
     
         6 . The machine of  claim 5 , wherein the number of pushers is equal to the number of rows of slots. 
     
     
         7 . The machine of  claim 1 , wherein one or more of the spacers comprises a hollow axle configured to receive a yarn. 
     
     
         8 . The machine of  claim 1 , wherein the slots on one side of the midpoint of the arch are angled toward the center of the arch at a given angle and the slots on the opposite side of the midpoint of the arch are angled toward the center of the arch by the same angle. 
     
     
         9 . A method for making three dimensional braided matrices with controlled shapes and porosity comprising using a machine comprising:
 (a) a frame,   (b) at least four carrier arches stacked in a linear manner and attached to the frame, wherein the two outer arches are fixed and the inner arches are moveable in sideways directions relative to the frame, and wherein each arch comprises a plurality of slots and spacers that alternate along the length of each arch,   (c) a plurality of moveable carriers, wherein each slot is configured to receive a carrier,   (d) a carrier pushing mechanism configured to push a carrier in a front to back direction relative to the frame.   
     
     
         10 . The method of  claim 9 , wherein the arches are aligned such that the slots on each arch align with corresponding slots in the proximal arch forming rows of slots. 
     
     
         11 . The method of  claim 9 , wherein the yarns begin forming the braided matrix at a braid point, wherein the lengths from the tip of each carrier to the braid point are within ±10% of each other, preferably within ±5% of each other, more preferably within ±2% of each other. 
     
     
         12 . The method of  claim 9 , wherein the total number of arches is 4, 5, 6, 7, 8, 9, or 10 arches. 
     
     
         13 . The method of  claim 9 , wherein the carrier pushing mechanism comprises a carrier pusher drive system and a plurality of pushers, wherein each pusher aligns with one row of slots. 
     
     
         14 . The method of  claim 13 , wherein the number of pushers is equal to the number of rows of slots. 
     
     
         15 . The method of  claim 9 , wherein one or more of the spacers comprises a hollow axle configured to receive a yarn. 
     
     
         16 . The method of  claim 9 , wherein the slots on one side of the midpoint of the arch are angled toward the center of the arch at a given angle and the slots on the opposite side of the midpoint of the arch are angled toward the center of the arch by the same angle. 
     
     
         17 . A three-dimensional braided matrix formed by a machine comprising:
 (a) a frame,   (b) at least four carrier arches stacked in a linear manner and attached to the frame, wherein the two outer arches are fixed and the inner arches are moveable in sideways directions relative to the frame, and wherein each arch comprises a plurality of slots and spacers that alternate along the length of each arch,   (c) a plurality of moveable carriers, wherein each slot is configured to receive a carrier,   (d) a carrier pushing mechanism configured to push a carrier in a front to back direction relative to the frame.   
     
     
         18 . The matrix of  claim 17 , wherein the a matrix forms an inter-connected, open pore structure that enables even and random distribution and in-growth of cells and provides structural and mechanical support for a period of about six to twelve months after affixation to the soft tissue or to bone adjacent to or associated with the soft tissue to be repaired. 
     
     
         19 . The matrix of  claim 17 , wherein the porosity of the braided matrix is porosity between 50% and 70% of the volume of the braided matrix 
     
     
         20 . The matrix of  claim 17 , where the pore size ranges from 177 μm and 250 μm. 
     
     
         21 . The matrix of  claim 17 , comprising a split region, where the braid separates into two or more braids.