Ablation Catheter Bond Joint Strength via Extended Adhesive
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Solution Overview
Problem
Ablation catheters face challenges in forming reliable bond joints between the electrode tip assembly and the catheter shaft due to inconsistencies in the inner diameter of the catheter shaft, leading to inconsistent bonding patterns and reduced bond joint strength, which can result in failure under stress.
Innovation Solution
The implementation of an adhesive bond joint with an extended length and area that incorporates additional structural components and gap filling, shifting the failure mode from the bond joint to a stronger area of the catheter shaft, and utilizing a two-step adhesive process with a quick curing adhesive followed by a secondary adhesive to further secure the materials and tailor the deflectable zone modulus.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a conventional bond joint is used between the electrode tip assembly and catheter shaft, then the manufacturing process is simple, but the bond joint strength is insufficient and variability is high due to inner diameter inconsistencies
Solution Approach 1:
The patent transitions from a conventional circumferential bond joint to an extended linear bond joint that propagates along the catheter shaft. This dimensional change from a circular interface to a linear extended interface increases the bonding area and distributes stress more effectively, compensating for inner diameter inconsistencies in the catheter shaft.
Solution Approach 2:
The patent applies adhesive material in advance to the electrode tip assembly or catheter shaft before assembly, ensuring proper adhesive distribution and curing. This preliminary action allows for controlled bonding and reduces the impact of dimensional variations in the catheter shaft inner diameter.
2Strength
If the bond joint area is increased to improve strength, then bond joint strength increases, but the complexity of the bonding process and adhesive application increases
Solution Approach 1:
The patent combines the adhesive application and bond joint formation into a single integrated process. The extended bond joint is created by applying adhesive along the length of the catheter shaft and bonding the electrode tip assembly in one continuous operation, rather than requiring multiple separate bonding steps.
Solution Approach 2:
The patent modifies the adhesive application parameters, such as adhesive viscosity, application rate, and curing conditions, to enable the extended bond joint to be formed with consistent quality. By optimizing these parameters, the complex extended bonding process becomes controllable and repeatable.
3Ease of manufacture
If a single adhesive system is used for bonding, then the manufacturing process is simple and quick, but the ability to address dimensional interference fit issues and tailor deflectable zone modulus is limited
Solution Approach 1:
The patent divides the adhesive system into multiple segments or layers, using different adhesives with different properties at different locations or depths. This segmentation allows each adhesive to be optimized for specific functions, such as one adhesive for initial bonding and another for flexibility or gap filling.
Solution Approach 2:
The patent applies different adhesive materials or properties at different locations within the bond joint. For example, a first adhesive may be applied at the distal end for strong bonding, while a second adhesive with different properties is applied at the proximal end to tailor the deflectable zone modulus or accommodate dimensional variations.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enhances the strength and reliability of the bond joint, improving the assembly robustness and overall product quality by increasing the bond joint strength while reducing variability, and allowing for the use of different adhesive systems to address dimensional interference fit issues.
Implementation Method 1
an adhesive bond joint bonding an outer diameter of the tip stem to an inner diameter of the distal end of the catheter shaft
Data Source
AI summary
The present disclosure relates generally to medical devices, and more specifically to ablation catheters including bond joints formed to have improved strength and resistance to failure during use. In many embodiments an expanded bond-joint length and area and gap filling are used to increase the strength of the bond joint while decreasing relative variability. The bond joint length area is increased in a controlled manner so as to increase the overall strength of the bond joint by shifting the failure mode from the bond joint to a stronger area of the ablation catheter, such as the catheter shaft. Related methods of manufacturing such ablation catheters (or other medical devices including a bond joint) are also disclosed and described herein.