Actuating Cable Welding with Thermoplastic Bead Anchoring

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Solution Overview

Problem

Existing methods for securing the proximal ends of actuating cables in medical devices like endoscopes and catheters are unreliable and prone to poor anchoring, leading to improper operation.

Innovation Solution

A method involving a serrated welding head with teeth and grooves is used to weld the actuating cables to a thermoplastic part, creating beads that securely enclose the cable ends, ensuring durable and efficient attachment.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional fastening techniques (screwing, threading) are used to secure actuating cables to the pivoting piece, then the assembly can be disassembled and adjusted, but the fastening becomes delicate and unreliable, leading to poor anchoring and improper operation

Engineering Contradiction:

Improvefastening reliabilityVSAvoidassembly complexity

Core Design Contradiction:

ReliabilityVSEase of operation

Solution Approach 1:

The patent replaces traditional mechanical fastening techniques (screwing, threading) with ultrasonic welding. The ultrasonic welding head applies high-frequency vibrations that melt and fuse the thermoplastic material of the pivoting piece with the actuating cable, creating a strong, reliable weld that eliminates the delicacy and unreliability of mechanical fastening while maintaining ease of assembly through an automated welding process

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent changes the physical state of the thermoplastic material through ultrasonic vibration, transforming it from a solid state to a melted state during welding, then allowing it to cool and solidify into a strong bond. This parameter change (temperature and phase) enables creating a reliable fastening that is both strong and simple to implement

Inventive Principle:

Principle #35Parameter changes

2Reliability

If ultrasonic welding with a serrated welding head is used to attach actuating cables to thermoplastic parts, then the anchoring becomes secure and reliable, but the manufacturing process becomes more complex

Engineering Contradiction:

Improvecable anchoring securityVSAvoidwelding process complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The serrated welding head is divided into multiple teeth that create separate weld beads along the actuating cable. Each tooth generates an individual weld bead that encloses the cable, providing distributed anchoring points along the cable length. This segmentation ensures that even if one weld point fails, the cable remains securely anchored at other points, enhancing overall reliability while the modular tooth design simplifies the welding head structure

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The ultrasonic welding process is self-regulating through the serrated welding head design. The teeth automatically create consistent weld beads by displacing thermoplastic material into hollows during the welding process. The process self-adjusts to the cable position and material properties, reducing the need for complex control systems and making the manufacturing process simpler despite the advanced welding technique

Inventive Principle:

Principle #25Self-service

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

The method provides a reliable and cost-effective fixation of actuating cables, enhancing the operational stability and durability of medical devices by ensuring secure anchoring of the cables.

Implementation Method 1

ensure the heating of the area of the part

Methodology Applied

Scientific EffectHeating: Heating

Implementation Method 2

penetration of the teeth into the thermoplastic material area to move the material into the hollows

Methodology Applied

Scientific EffectMelting: Melting

Implementation Method 3

apply the serrated welding head with pressure on the end of the actuating cable

Methodology Applied

Scientific EffectPressure: Pressure Increase

Data Source

PatentEP4370312B1Method by which actuating cables are fixed by welding to a component in particular of the distal head of a medical device

Publication Date: 2025.11.19 AXESS VISION TECHNOLOGY

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AI summary

The invention relates to a method for fixing one end of an actuating cable (13), comprising the following steps: - making available a component (12) provided with at least one region of thermoplastic material for the fixing of one end (13p) of an actuating cable (13); - making available a toothed welding head formed of teeth that are alternately separated by hollows; - positioning the end (13p) of an actuating cable (13) on a region of thermoplastic material of the component; - heating the region of the component and applying the toothed welding head with pressure to the end (13p) of the actuating cable (13) in order to ensure the penetration of the teeth into the region of thermoplastic material, so as to move the material into the hollows in order to obtain at least one bead (16) of thermoplastic material encasing the actuating cable (13).