Prosthetic device and method of manufacturing the same

Abstract

A biocompatible surgical silk mesh prosthetic device employs a knit pattern that substantially prevents unraveling and preserves the stability of the mesh device, especially when the mesh device is cut. An example prosthetic device employs a knitted mesh including at least two yarns laid in a knit direction and engaging each other to define a plurality of nodes. The at least two yarns include a first yarn and a second yarn extending between and forming loops about two nodes. The second yarn has a higher tension at the two nodes than the first yarn. the second yarn substantially prevents the first yarn from moving at the two nodes and substantially prevents the knitted mesh from unraveling at the nodes.

1 . A three-dimensional knitted structure comprising:
 a first knitted fabric comprising a first set of yarns in a first knit direction,   a second knitted fabric comprising a second set of yarns in a second knit direction,   a third yarn engaging the first knitted fabric and the second knitted fabric defining openings between the first knitted fabric and the second knitted fabric thereby forming a three-dimensional knitted structure,   wherein at least one of the first knitted fabric, the second knitted fabric or the third yarn comprises silk and   wherein the three-dimensional knitted structure is biocompatible.   
     
     
         2 . The three-dimensional knitted structure according to  claim 1 , wherein the first knitted fabric, the second knitted fabric, or both are formed on a warp knitting machine. 
     
     
         3 . The three-dimensional knitted structure according to  claim 2 , wherein the first warp knitted fabric or the second warp knitted fabric is knitted on a single needle bed. 
     
     
         4 . The three-dimensional knitted structure according to  claim 2 , wherein the first warp knitted fabric or the second warp knitted fabric is knitted on a double needle bed. 
     
     
         5 . The three-dimensional knitted structure according to  claim 1 , wherein the first knitted fabric has a mesh design achieved through variation in yarn feed rate. 
     
     
         6 . The three-dimensional knitted structure according to  claim 1 , wherein the second knitted fabric has a mesh design achieved through variation in yarn feed rate. 
     
     
         7 . The three-dimensional knitted structure according to  claim 1 , wherein the first knitted fabric has a mesh design achieved through variation in stitch type or stitch spacing. 
     
     
         8 . The three-dimensional knitted structure according to  claim 1 , wherein the second knitted fabric has a mesh design achieved through variation in stitch type or stitch spacing. 
     
     
         9 . The three-dimensional knitted structure according to  claim 1 , wherein the first knit direction is in a wale direction. 
     
     
         10 . The three-dimensional knitted structure according to  claim 1 , wherein the first knit direction is in a weft direction. 
     
     
         11 . The three-dimensional knitted structure according to  claim 1 , wherein the second knit direction is in a wale direction. 
     
     
         12 . The three-dimensional knitted structure according to  claim 1 , wherein the second knit direction is in a weft direction. 
     
     
         13 . The three-dimensional knitted structure according to  claim 1 , wherein the first knitted fabric is a warp knit. 
     
     
         14 . The three-dimensional knitted structure according to  claim 1 , wherein the first knitted fabric is a weft knit. 
     
     
         15 . The three-dimensional knitted structure according to  claim 1 , wherein the second knitted fabric is a warp knit. 
     
     
         16 . The three-dimensional knitted structure according to  claim 1 , wherein the second knitted fabric is a weft knit. 
     
     
         17 . The three-dimensional knitted structure according to  claim 1 , wherein the silk is formed from silkworm silk fibroin. 
     
     
         18 . The three-dimensional knitted structure according to  claim 17 , wherein the silk is formed from Bombyx mori silkworm silk fibroin. 
     
     
         19 . The three-dimensional knitted structure according to  claim 17 , wherein the silk fibroin is sericin-depleted. 
     
     
         20 . The three-dimensional knitted structure according to  claim 1 , wherein the biocompatible knitted structure provides for tissue in-growth. 
     
     
         21 . The three-dimensional knitted structure according to  claim 1 , wherein the three-dimensional knitted structure is tubular. 
     
     
         22 . A three-dimensional knitted structure comprising:
 a knitted fabric having a first end and a second end,   a yarn engaging the first end and the second end,   wherein the knitted fabric comprises silk.   
     
     
         23 . The three-dimensional knitted structure according to  claim 22 , wherein the knitted fabric is knit on a single needle bed. 
     
     
         24 . The three-dimensional knitted structure according to  claim 22 , wherein the knitted structure is knit on a single needle bed.