Apparatus and method for processing a workpiece using pressure and heat

Abstract

An apparatus (10) to process a workpiece (12) includes a housing (18), a deformable membrane (20) disposed in the housing (10) and defining a chamber (22) configured to receive the workpiece (12), a heater (34) configured to apply heat to the workpiece (12) in the chamber (22), and a pump (32) configured to control a fluid pressure in the housing (18), where the membrane (20) is configured to apply a contact pressure to the workpiece (12) when in the chamber (22). A corresponding method includes inserting the workpiece (12) into the chamber (22) defined by the membrane (20) and processing the workpiece (12) in the chamber (22) by applying pressure to the workpiece (12) when in the chamber (22) via the deformable membrane (20) within the housing (10) and applying heat to the workpiece (12) by the heater (34).

Description

BUR02 FP-165A(WO)APPARATUS AND METHOD FOR PROCESSING A WORKPIECE USING PRESSURE AND HEAT CROSS REFERENCE TO RELATED APPLICATION

[0001] The present application claims the priority benefits of U.S. provisional patent application ser. no. 63 / 778,658, filed on March 27, 2025, which is incorporated herein by reference.FIELD OF THE DISCLOSURE

[0002] The present disclosure relates to device manufacturing, and, more particularly, to an apparatus and method for processing a workpiece using pressure and heat.BACKGROUND

[0003] Manufacturing devices can involve many processes such as, for example, bonding and molding workpieces. The process of bonding involves joining two or more materials or components of a workpiece together. Common bonding techniques include adhesive bonding, mechanical bonding, welding, soldering, and brazing. The process of molding involves shaping the workpiece into its desired form. Common molding techniques include injection molding, compression molding, and rotational molding. Bonding and / or molding processes may also be accomplished by using heat shrink tubing. For example, a workpiece may be inserted into the tubing, and the tubing can shrink uniformly when heated based a shrink ratio of the tubing. This allows the workpiece to be molded to a desired shape. Further, the workpiece may have multiple layers that can be bonded together by the heat shrink tubing. The workpiece may be combined with one or more workpieces for producing the device.SUMMARY

[0004] An apparatus can use pressure and heat to process a workpiece during production of a device such as, for example, a medical device, a cable device, a battery device, and the like. The apparatus has a housing that contains a flexible or deformable membrane having an inner surface that defines a chamber or an open area for receiving a workpiece. The inner surface can contact and apply pressure to the workpiece in the chamber based on a contraction of the membrane into a relaxed state and / or via a fluid pressure applied to an outer surface of the membrane. The fluid pressure is the pressure of a fluid (e.g., air) in a fluid region surrounding the outer surface of the membrane in the housing. The fluid pressure is provided by a pump that creates a positive pressure within the housing and also generates a vacuum within the housing. The pump may be controlled by a controller and a pressure regulator, which in turn controls the contact pressure. The pump can provide a vacuum pressure within the housing to expand the membrane while theworkpiece is entering or exiting the chamber so that the workpiece can be readily inserted and withdrawn from the chamber. The pump may provide a positive pressure while the workpiece is being processed in the chamber to apply pressure to the workpiece to shape and / or smooth the workpiece.

[0005] The apparatus has a heater such as, for example, an induction coil that can apply heat to the workpiece in the chamber. The combination of the heat treatment and the pressure applied to the workpiece can form or mold the workpiece into a desired shape, including causing material disposed over the workpiece to reflow. Further, the workpiece may have multiple components, and the heat and the pressure applied to the workpiece can bond the components. The apparatus may improve processing of the workpiece compared to traditional processing. For example, the workpiece may have multiple catheter components that are traditionally processed by applying a section of "sacrificial" heat shrink tubing over the catheter components, and then subsequently removing the heat shrink tubing, which may be a timely and costly process. The apparatus may eliminate the need to use such sacrificial heat shrink tubing for processing the workpiece, thereby eliminating costs and time associated with using heat shrink tubing.

[0006] In one example of the present disclosure, an apparatus or assembly or system (hereinafter referred to as “apparatus”) for processing a workpiece for producing a device includes a housing, a membrane disposed within the housing and defining a chamber for receiving the workpiece, and a heater that can apply heat to the workpiece in the chamber. The apparatus includes a pump for selectively applying expanding and contracting the membrane. A positive pressure may be applied to the membrane to apply or increase a contact pressure to the workpiece.

[0007] In another example, in any of the apparatuses according to the disclosure, the heater has an inner portion disposed in the housing. The heater may be an induction coil that surrounds the membrane.

[0008] In a further example, in any apparatus, a pressure regulator can control the fluid pressure to cause the fluid pressure to have a first value while the workpiece is being processed in the chamber, and a second value while the workpiece is entering or exiting the chamber, with the first value being greater than the second value.

[0009] In still another example, in any apparatus, the housing defines a first opening, and the membrane defines a second opening, with the chamber receiving the workpiece via the first and second openings.

[0010] In particular arrangements, a pump may be provided to decrease the pressure in the housing to expand the membrane for inserting and removing the workpiece from the interior of the membrane. The pump may then be configured to allow the membrane to contract, such as by allowing the pressure in the housing to return to an ambient pressure, when a workpiece is in the chamber whereby the membrane contracts about the workpiece to apply pressure to the workpiece. Alternatively and / or additionally, the pump may be configured to increase the pressure in the housing to apply pressure to the membrane and in turn to the workpiece.

[0011] In a further example, in any apparatus, the chamber comprises a flexible sleeve membrane and may have a tubular shape. The membrane may be an elastomer material, such as a silicone material.

[0012] In still another example, in any apparatus, the device is a catheter.

[0013] In a further example of an apparatus for processing a workpiece in accordance with the present invention, the apparatus comprises a housing having opposed walls and openings on the opposed walls, a deformable membrane configured as a sleeve extending between the openings on the opposed walls, where the membrane is configured to receive the workpiece such that at least a portion of the workpiece is disposed internally of the housing within the sleeve, and a heater configured to apply heat to the portion of the workpiece disposed within the sleeve.

[0014] In a further arrangement, the apparatus includes a pump and the housing defines an internal volume about the membrane, where the pump is configured to decrease the pressure in the internal volume to expand the membrane for inserting and removing the workpiece from the sleeve. The pump is configured to allow the membrane to contract when a workpiece is in the sleeve whereby the membrane contracts about the workpiece to apply pressure to the workpiece. In a still further particular arrangement, the pump is configured to increase the pressure in the internal volume to apply pressure to the membrane and in turn to the workpiece when the workpiece is in the sleeve.

[0015] In any of the embodiments the heater may be configured as a heating coil disposed in the housing and surrounding the membrane.

[0016] In another example of the present disclosure, a method for producing a device includes providing a workpiece to a chamber defined by a membrane that is disposed in a housing. The method further includes processing the workpiece in the chamber by applying pressure to theworkpiece when in the chamber, such as by applying a fluid pressure to the membrane within the housing, and by applying heat to the workpiece.

[0017] In still another example of the present disclosure, a method for processing a workpiece includes inserting the workpiece into a chamber defined by a deformable membrane disposed in the housing and processing the workpiece in the chamber by applying pressure to the workpiece when in the chamber via the deformable membrane within the housing and applying heat to the workpiece by a heater.

[0018] The method may further include reducing a pressure in a volume of the housing surrounding the membrane to expand the membrane prior to inserting the workpiece into the chamber.

[0019] In a particular arrangement, applying pressure to the workpiece may comprise contracting the membrane about the workpiece. Still further, applying pressure to the workpiece may additionally comprise increasing a pressure in a volume of the housing surrounding the membrane to contract the membrane about the workpiece.

[0020] In any of the embodiments, the workpiece may be constructed of multiple components, with one or more components being deformable by heat and / or pressure. The deformable components may bond to other components of the workpiece under heat and / or pressure, such as by being molded thereto. The deformable components may comprise a thermoplastic material. In any of the embodiments, the method may be used for producing a catheter.

[0021] Thus, the apparatus may decrease time and / or costs associated with processing the workpiece for production of the device such as, for example, a catheter. This is accomplished by the apparatus including the membrane that has the inner surface for contacting and applying pressure to the workpiece in the chamber defined by the membrane. The contact pressure applied to the workpiece is based on the fluid pressure in the fluid region. The fluid region surrounds the outer surface of the membrane, and is in the housing of the apparatus. The apparatus has the pump for providing the fluid pressure in the fluid region. The apparatus has the heater such as, for example, an induction coil that can apply heat to the workpiece in the chamber. The pressure and heat treatment applied to the workpiece can mold the workpiece into a desired shape and / or bond components of the workpiece while also providing a smooth surface.

[0022] These and other objects, advantages, purposes, and features of this disclosure will become apparent upon review of the following specification in conjunction with the drawings.BRIEF DESCRIPTION OF DRAWINGS

[0023] FIG. 1 A is an elevation view of a workpiece before processing by an apparatus;

[0024] FIG. IB is another elevation view of the workpiece of FIG. 1 after processing by an apparatus;

[0025] FIG. 2 is a perspective view of an apparatus for processing the workpiece of FIG. 1 ;

[0026] FIG. 3 is a front side sectional view of the apparatus of FIG. 2 having a membrane at a processing state;

[0027] FIG. 4 is another front side sectional view of the apparatus of FIG. 2 having the membrane at a receiving state;

[0028] FIG. 5 is another front side sectional view of the apparatus of FIG. 2 having the membrane at a relaxed state; and

[0029] FIG. 6 is a perspective view of a workpiece processed via the apparatus of any of FIG. 2.DETAILED DESCRIPTION

[0030] Referring now to the drawings and illustrative examples depicted therein, an apparatus 10 can process a workpiece 12 during production of a device such as, for example, a medical device, a cable device, a battery device, and the like. (FIGS. 1A, IB, 2). The apparatus 10 can process the workpiece 12 to form the workpiece 12 into a desired shape. For example, as shown in FIG. 1A, the workpiece 12 has a layer component 14 that initially has a larger diameter than a base component 16 of the workpiece 12. The apparatus 10 can process the workpiece 12 so that the difference in diameter between the base component 16 and the layer component 14 is reduced or eliminated, as shown in FIG. IB. The apparatus 10 can also process the workpiece 12 to bond two or more components of the workpiece 12 together. For example, the layer component 14 may be or include a plastic or a polymer that allows the layer component 14 to be adhered to the base component 16 when the apparatus 10 applies heat and pressure. For example, the application of heat may cause the layer component 14 to melt or reflow about the base component 16.

[0031] An exemplary workpiece 12 is shown in FIG. 6, which is illustrated as a catheter having multiple components including a tip 100, a distal sleeve 102, a marker 104, one or more main segments 106, and a braided portion 108. Catheter 12 includes a hollow passage through which components or diagnostic equipment or the like may be passed, such as during a medical procedure. During construction, the components may be selectively placed over an inner mandrelused for forming workpiece 12, where inner mandrel comprises an elongate cylindrical base sized to fit within the inner diameter of the components. The mandrel may be made of steel, such as a steel coated with a polytetrafluoroethylene (PTFE) coating that is able to provide support during processing of the workpiece 12. The one or more of the components of the catheter 12 may be deformable by heat and / or pressure, such as to bond to other components of the workpiece under heat and / or pressure, such as by being molded thereto. The deformable components may comprise a thermoplastic material. During assembly, various of the components are bonded or joined together using the apparatuses discussed below. For example, a main segment 106 and / or marker 104 may be molded to the braided portion 108, and / or the distal sleeve 102 may be molded to a main segment 106. Desirably, the outer diameter of the workpiece is consistent with little variation between components and / or with smooth transitions therebetween.

[0032] The apparatus 10 has a housing 18 within which a flexible membrane 20 is disposed, with the membrane 20 comprising a sleeve having an inner surface 24 defining an internal receiving chamber, area, space, interior or volume 22 for receiving the workpiece 12. (FIGS. 2-5). The apparatus 10 can process the workpiece 12 in the receiving chamber 22 by applying heat and / or pressure to the workpiece 12. (FIG. 3). The inner surface 24 of the membrane 20 can contact and apply pressure to the workpiece 12. The membrane 20 is flexible or deformable so that the shape of the membrane 20 can be changed, and pressure applied to the workpiece 12 can be adjusted. (FIGS. 3 and 4). The membrane 20 may be tubular and made of one or more elastomer materials such as, for example, silicone materials. In the case where the workpiece 12 includes an internal hollow passage, such as with a catheter, a mandrel 37 is disposed in the inner diameter 39 of workpiece 12, and thus the components thereof, where the outer diameter of the mandrel 37 is sized to be similar to the inner diameter 39 of the workpiece 12 to provide support to the workpiece 12 during processing

[0033] The apparatus 10 has an internal volume defining a fluid region 26 in the housing 18 that surrounds an outer surface 30 of the membrane 20. (FIGS. 3-5). The inner surface 24 of the membrane 20 can apply the contact pressure to the workpiece 12 either based on contraction of the membrane 20 in a relaxed state and / or based on a fluid pressure in the fluid region 26. (FIG.3). For example, an increase of the fluid pressure applied to the outer surface 30 of the membrane 20 will cause an increase of the contact pressure applied to the workpiece 12 by theinner surface 24 of the membrane 20. Correspondingly, a decrease in pressure within the internal volume of the housing 18 will cause the membrane 20 to expand, such as to aid in the insertion and withdrawing of the workpiece from the chamber 22.

[0034] Apparatus 10 includes a fitting 32 via which a pump 33 may be connected, such as via a hose or tube 35, with the pump 33 being operable as a vacuum / pressure pump that can be used to selectively control the fluid pressure in the housing 18, which in turn controls the expansion and contraction of membrane 20 and thereby the contact pressure applied by the membrane 20 to the workpiece 12. For example, the pump 33 can be used to cause a lower fluid pressure in the housing 18 (such as relative to ambient pressure surrounding the housing 18) to thereby expand membrane 20 (which is open to ambient pressure on its ends) as shown in FIG. 4 while the workpiece 12 is entering or exiting the chamber 22, compared to while the workpiece 12 is being processed, so that the contact pressure can be removed or reduced and the workpiece 12 can more readily enter or exit the chamber 22. With reference to FIG. 3, which shows the workpiece 12 being processed, the vacuum created in housing 18 by pump 33 is removed such that membrane 20 contracts toward its relaxed state and thereby applies pressure to workpiece 12. The pressure applied by membrane 20 will be influenced by factors such as the durometer of membrane 20 as well as the size of the outside diameter of workpiece 12 relative to the inside diameter of membrane 20 in its relaxed state (FIG. 5). In turn, pump 33 may be used to increase the pressure within housing 18 relative to ambient pressure to thereby compress membrane 20 about the workpiece 12 to apply additional pressure thereto.

[0035] The apparatus 10 has a heater 34 that can apply heat to the workpiece 12 while in the chamber 22. (FIGS. 2-5). For example, as shown in the illustrated embodiment of FIGS. 3-5, the heater 34 is an induction coil having coils 36 disposed internally within the housing 18 and surrounding the membrane 20. Coils 36 may cause the workpiece 12 to be heated while the contact pressure is applied on the workpiece 12 by membrane 20 to shape, bond, and / or smooth the workpiece 12 into a desired form. (FIG. 3). Coils 36, for example, may induce heat in a portion of workpiece 12. For example, workpiece 12 may comprise a hollow tubular component, such as a catheter, within which an inner conductive component, such as a metal mandrel 37, is disposed while processing the workpiece 12. Coils 36 may induce heat in the metal mandrel 37 so that heat is applied to the catheter 12 while contact pressure is applied by membrane 20 to shape, bond, and / or smooth the catheter into a desired form. In addition, the mandrel 37 preventsthe hollow workpiece 12 from collapsing when pressure is applied to the exterior of the workpiece 12.

[0036] Although the heater 34 is shown as an induction coil in the illustrated embodiment, it should be appreciated that alternative heaters may be employed. For example, heater 34 may be eliminated from apparatus 10, and workpiece 12 may be heated before entering chamber 22. As such, the membrane 20 can apply pressure to workpiece 12 that has been previously heated to shape, bond, and / or smooth the components of the workpiece 12. An alternative heater may supply hot air into the interior of housing 18, or may heat coils 36 to cause coils 36 to increase in temperature.

[0037] Thus, membrane 20 and heater 34 may respectively be used to apply pressure and heat to process the workpiece 12 into a desired form based on the device in production. The apparatus 10 may improve processing of the workpiece 12 compared to traditional processing of the workpiece 12. For example, the layer and the base components 14, 16 may be components that are traditionally processed by applying sacrificial heat shrink tubing and then removing it with a skiving tool after the components have been molded and / or bonded together by the heat shrink tubing. Those components may include various layers or elements such as, for example, various catheter components. The apparatus 10 can shape, bond, and / or mold the workpiece 12 without sacrificial heat shrink tubing. As such, the apparatus 10 may reduce costs and / or time associated with processing the workpiece 12 that may be traditionally processed using heat shrink tubing.

[0038] Referring to FIG. 2, the apparatus 10 has right, left, rear, front, upper, and lower sides or walls 38a-f that cooperate to define the housing 18. Walls 38a, 38b define respective openings 40, 56 for receiving the workpiece 12 so that the workpiece 12 can be provided into the chamber 22 for processing, with membrane 20 being sealed to walls 38a, 38b at the openings 40, 56 as noted below. (FIGS. 2-5).

[0039] The upper wall 38e has first and second upper portions 42, 44 defining apertures or connectors via which first and second outboard leads 46, 48 of the induction coil 34 extend or are connected, with leads 46, 48 extending into housing 18. (FIG. 2). Leads 46, 48 of the induction coil 34 are coupled to a power supply for providing current to the induction coil 34 so that the induction coil 34 can provide heat to the workpiece 12 in the chamber 22 defined by the membrane 20. (FIGS. 2-4).

[0040] Referring to FIG. 3, the membrane 20 has a pair of distal ends coupled to respective ones of the side walls 38a, 38b of the housing 18. One end of the membrane 20 defines an opening 50 at wall 38a so that the workpiece 12 can enter or exit the chamber 22 via a side 52 of the apparatus 10. For example, the workpiece 12 may enter the side 52 of the apparatus 10 via the opening 50 of the membrane 20 and the opening 40 of side wall 38a. The opposite end of the membrane 20 may similarly define an opening 54 at opening 56 of side wall 38b so that the workpiece 12 can enter or exit the chamber 22 via the other side 58 of the apparatus 10 that is opposite to side 52.

[0041] The workpiece 12 can be disposed in a processing position that allows the apparatus 10 to process the workpiece 12 such as, for example, as shown in FIG. 3 in which the workpiece 12 extends through the housing 18 such that the workpiece 12 has right and left portions outside of the housing 18, and a middle portion of the workpiece 12 in the chamber 22 that can be processed by the apparatus 10.

[0042] In other examples, the workpiece 12 may be disposed in any other suitable processing position. For example, the workpiece 12 may not extend through the entire chamber 22 so that only one of the ends of the workpiece 12 can be processed into a desired shape. It should be appreciated that an alternative apparatus need not have a chamber that extends all the way through the housing, but rather comprises a blind volume for receiving an end of a workpiece.

[0043] The induction coil 34 may provide heat to the workpiece 12 while the workpiece 12 is disposed in a processing position, such as shown in FIG. 3. As current flows through the inboard coils 36 of the induction coil 34 that are wound around the membrane 20, the induction coil 34 generates heat that then heats the workpiece 12 in the chamber 22 defined by the membrane 20. It should be appreciated that the induction coil may be constructed in various manners to heat the workpiece 12, including for example by generating an alternating current or creating a magnetic field.

[0044] The pump 33 can apply pressure via fitting 32 while the induction coil 34 is applying heat to the workpiece 12 for processing the workpiece 12 into a desired form. The applied pressure causes the membrane 20 to be in a processing state, as shown in FIG. 3, where the inner surface 24 of the membrane 20 is applying contact pressure to the workpiece 12 to shape, bond, and / or smooth the workpiece 12. For example, the applied pressure may be varied such as between avalue of pressure outside of the housing 18 to any other suitable positive pressure value that can allow the membrane 20 to process the workpiece 12.

[0045] Referring to FIG. 4 and as noted above, the pump 33 can supply a vacuum pressure via fitting 32 so that the membrane 20 can be in a receiving state where the membrane 20 is expanded where the contact pressure applied by the inner surface 24 to the workpiece 12 is reduced or eliminated so that the workpiece 12 can be readily removed from or inserted into the housing 18.

[0046] Once the workpiece 12 is provided to the chamber 22 and is in a processing position, the pump 33 may provide pressure, which may be controlled by a regulator, to cause the fluid pressure within the housing 18 to have a predetermined processing value so that the workpiece 12 can be processed. (FIG. 3). Further, the induction coil 34 may simultaneously apply a heat treatment via heat to the workpiece 12 while the fluid pressure has the processing value for processing the workpiece 12. After the workpiece 12 has been processed, the pump 33 may cause the fluid pressure to become a vacuum so that the workpiece 12 can be readily removed from the chamber 22. (FIG. 4).

[0047] The contact pressure applied by the inner surface 24 to the workpiece 12 via the pump 33 may be selectively adjusted and controlled, such as via a pressure regulator and a controller, as may be desired for the given base component 16 and layer component 14 being applied thereto.

[0048] Referring to FIG. 5, the membrane 20 is at a relaxed state while the fluid pressure of the fluid region 26 is at a relaxed value, and workpiece 12 is not entering, exiting, or being processed in the chamber 22. The relaxed value may be equal to a value of the pressure outside of the housing 18 with the pump 33 not supplying pressurized air or generating a vacuum.

[0049] Diameter of inner surface 24 of membrane 20 while at the relaxed state may be less than or equal to diameter of the base component 16 of workpiece 12 to reduce the likelihood of layer component 14 wrinkling from contact pressure applied by membrane 20 while at a processing state. The value of contact pressure applied by inner surface 24 is based on differences in diameters between the workpiece 12 and membrane 20 at the relaxed state. For example, inner surface 24 may apply a contact pressure to the workpiece 12 that is greater than a contact pressure applied to a workpiece having a smaller diameter. Other factors may impact the value of contact pressure such as, for example, the fluid pressure of the fluid region 26, the durometervalue of the membrane 20, and the distance between the inner and outer surfaces 24, 30 of the membrane 20 (i.e., thickness of the membrane 20).

[0050] Although examples of the apparatus 10 and workpiece 12 are shown in FIGS. 1-5, one or more of the elements illustrated in FIGS. 1-5 may be combined, divided, re-arranged, omitted, and / or implemented in any other way. For example, although the workpiece 12 and membrane 20 are shown as tubularly shaped, the workpiece 12 and / or the membrane 20 may be any other suitable shape that can be disposed in the housing 18. In another example, the housing 18 may be any other suitable shape. In yet another example, the membrane 20 may not extend through the entire housing 18, and the right openings 40, 50 or the left openings 54, 56 may be omitted. In still another example, the induction coil 34 may be coupled to alternative walls of the housing 18.

[0051] Further, the apparatus 10 and workpiece 12 shown in FIGS. 1-5 may include one or more elements in addition to and / or instead of the elements illustrated in FIGS. 1-5, and / or may include more than one of the structures illustrated in FIGS. 1-5. For example, the induction coil 34 may be replaced by any other suitable heater device, such as a resistance heater, an infrared heater, and the like. In another example, the apparatus 10 may have one or more additional membranes that can receive workpieces.

[0052] Accordingly, an apparatus described herein has a membrane and a heater that can respectively apply contact pressure and a heat treatment to mold a workpiece into a desired shape and / or bond components of the workpiece. The membrane and an inner portion of the heater are disposed in a housing of the apparatus. The membrane defines a chamber that can receive the workpiece for processing. The membrane is deformable so that the inner surface of the membrane can adjust the contact pressure applied on the workpiece. The contact pressure applied by the inner surface of the membrane is based on a fluid pressure in the housing. The fluid pressure is controlled by a pump coupled to the housing. The apparatus may eliminate the need to process workpieces that use certain traditional processes that are costly and / or time consuming such as, for example, sacrificial heat shrink tubing. As such, the apparatus may improve the efficiency of producing devices that have workpieces using those certain traditional processes.

[0053] Although some of the structures shown in the apparatus and workpiece share the same numbering, this does not imply the structures are identical. For example, the workpiece 12discussed in conjunction with FIG. 1A differs from the workpiece 12 discussed in conjunction with FIG. IB.

[0054] Connection relationships between elements are described herein using various terms, such as "coupled", "cooperate", "disposed", etc. As used herein, connection relationships can be direct relationships and / or indirect relationships where one or more intervening elements are between the first and second elements.

[0055] Spatial relationships of elements are described herein using various terms such as, for example, "upper", "lower", "left", "right", "front", "rear", "opposing", "outward", "inward", etc. As used herein, spatial relationships of the elements do not limit the orientations of the elements as other orientations of the elements may be used.

[0056] It should be understood that "including", "comprising", and "having" (and all other forms, such as tenses) are used herein to be open-ended terms. Thus, whenever a claim recites any form of "include", "comprise", or "have" (e.g., comprises, includes, has, comprising, including, having) as a preamble or within a claim recitation of any kind, it is to be understood that additional elements, terms, etc. may be present without falling outside the scope of the corresponding claim.

[0057] As used herein, singular references (e.g., "a", "an", "first", "second") do not exclude a plurality. The term "a" or "an" entity refers to one or more of that entity. The terms "a" (or "an"), "one or more", and "at least one" can be used interchangeably. The term "and / or" when used in a form such as, for example, A, B, and / or C refers to any combination or subset of A, B, C such as (1) A alone, (2) B alone, (3) C alone, (4) A with B, (5) A with C, (6) B with C, and (7) A with B and with C.

[0058] Changes and modifications in the specifically described examples can be carried out without departing from the principles of the present disclosure which is intended to be limited only by the scope of the appended claims, as interpreted according to the principles of patent law including the doctrine of equivalents.

Claims

CLAIMS1. An apparatus to process a workpiece for producing a device, said apparatus comprising:a housing;a deformable membrane disposed in said housing and defining a chamber configured to receive the workpiece;a heater configured to apply heat to the workpiece in said chamber;a pump configured to control a fluid pressure in said housing; andwherein said membrane is configured to apply a contact pressure to the workpiece when in said chamber.

2. The apparatus of claim 1 , wherein said heater has an inner portion disposed in said housing.

3. The apparatus of claim 2, wherein said heater is an induction coil, and said inner portion surrounds said deformable membrane.

4. The apparatus of claim 3, wherein said housing defines first and second openings, and said induction coil extends between said first and second openings.

5. The apparatus of claim 1, wherein said pump is configured to decrease the pressure in said housing to expand said membrane for inserting and removing the workpiece from the chamber.

6. The apparatus of claim 5, wherein said pump is configured to allow said membrane to contract when a workpiece is in the chamber whereby said membrane contracts about the workpiece to apply pressure to the workpiece.

7. The apparatus of either of claims 5 or 6, wherein said pump is configured to increase the pressure in said housing to apply pressure to said membrane and in turn to said workpiece.

8. The apparatus of claim 1, wherein said pump is configured to apply said fluid pressure to a first value while the workpiece is being processed in said chamber, and a second value while theworkpiece is entering or exiting said chamber, wherein said first value is greater than said second value.

9. The apparatus of claim 8, wherein said membrane is configured to apply said contact pressure to the workpiece while said fluid pressure is at said second value.

10. The apparatus of claim 1, wherein said housing defines a first opening, and said deformable membrane defines a second opening, wherein said chamber is configured to receive the workpiece via said first and second openings.

11. The apparatus of claim 10, wherein said housing comprises opposing sides, and wherein a first of said opposing sides has said first and second openings, and wherein said chamber extends between said opposing sides.

12. The apparatus of claim 11, wherein said housing defines a third opening, and said deformable membrane defines a fourth opening, wherein said second of said opposing sides has said third and fourth openings, and wherein said chamber extends between said third and fourth openings and said first and second openings.

13. The apparatus of claim 11, wherein said deformable membrane comprises a sleeve membrane.

14. The apparatus of claim 13, wherein said deformable membrane has a tubular shape.

15. The apparatus of claim 1, wherein said deformable membrane comprises an elastomer material.

16. The apparatus of claim 15, wherein said elastomer material is a silicone material.

17. The apparatus of claim 1, wherein the device is a catheter.

18. An apparatus for processing a workpiece, said apparatus comprising:a housing having opposed walls and openings on the opposed walls;a deformable membrane configured as a sleeve extending between the openings on the opposed walls, wherein the membrane is configured to receive the workpiece such that at least a portion of the workpiece is disposed internally of the housing within the sleeve; anda heater configured to apply heat to the portion of the workpiece disposed within the sleeve.

19. The apparatus of claim 18, further comprising a pump and wherein the housing defines an internal volume about the membrane, wherein the pump is configured to decrease the pressure in the internal volume to expand the membrane for inserting and removing the workpiece from the sleeve.

20. The apparatus of claim 19, wherein the pump is configured to allow the membrane to contract when a workpiece is in the sleeve whereby the membrane contracts about the workpiece to apply pressure to the workpiece.

21. The apparatus of either of claims 19 or 20, wherein the pump is configured to increase the pressure in the internal volume to apply pressure to the membrane and in turn to the workpiece when the workpiece is in the sleeve.

22. The apparatus of claim 18, wherein the heater comprises a heating coil disposed in the housing and surrounding the membrane.

23. A method for processing a workpiece, said method comprising:inserting the workpiece into a chamber defined by a deformable membrane disposed in a housing; andprocessing the workpiece in the chamber, wherein said processing the workpiece includes:applying pressure to the workpiece when in the chamber via the deformable membrane within the housing; andapplying heat to the workpiece by a heater.

24. The method of claim 23, further comprising reducing a pressure in a volume of the housing surrounding the membrane to expand the membrane prior to said inserting the workpiece into the chamber.

25. The method of either of claims 23 or 24, wherein said applying pressure to the workpiece comprises contracting the membrane about the workpiece.

26. The method of either of claims 23 or 24, wherein said applying pressure to the workpiece comprises increasing a pressure in a volume of the housing surrounding the membrane to contract the membrane about the workpiece.

27. The method of claim 23, wherein said applying pressure to the workpiece comprises applying fluid pressure, and wherein the fluid pressure is a first fluid pressure having a first value, wherein said method further comprises generating a second fluid pressure in the housing having a second value lower than the first value, wherein said inserting the workpiece to the chamber occurs while the housing has the second fluid pressure.

28. The method of claim 27, further comprising removing the workpiece from the chamber.

29. The method of claim 28, wherein said removing the workpiece from the chamber occurs while the housing has the second fluid pressure.

30. The method of claim 23, wherein the device is a catheter.

31. The method of claim 30, wherein the catheter comprises multiple components and at least one of the components is deformable under heat and pressure.

32. The method of claim 31 , further comprising forming the catheter to have a uniform outer diameter via applying the pressure and the heat to the workpiece.

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