Atraumatic Tip Assembly Guidewire Instant Glue Bonding
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Solution Overview
Problem
Existing surgical guidewires with atraumatic tips face challenges in manufacturing efficiency and material costs, particularly with epoxy tips that require extended drying times and strict diametric tolerances, which can lead to detachment from the guidewire when used with dilation catheters.
Innovation Solution
The development of a surgical guidewire with an atraumatic tip assembly that includes a position sensor, an outer coil assembly, a communication wire, an adhesive, a core wire, and a hypotube, where the atraumatic tip is efficiently attached using instant glue, reducing manufacturing time and costs, and featuring a design that minimizes the risk of detachment from the guidewire.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If epoxy tip is used for atraumatic coating, then tissue protection is achieved, but manufacturing time increases and drying requirements extend
Solution Approach 1:
The patent changes the material parameter from epoxy to instant glue (cyanoacrylate adhesive), which fundamentally alters the curing characteristics. Instant glue provides immediate bonding strength without requiring extended drying periods or oven curing, thus resolving the time loss issue while maintaining the atraumatic tip's tissue protection function
Solution Approach 2:
The patent employs instant glue as a disposable, single-use adhesive that provides sufficient bonding strength for the surgical procedure and then degrades. This eliminates the need for permanent, long-lasting adhesives like epoxy, reducing both manufacturing time and material complexity while achieving the necessary atraumatic protection
2Reliability
If epoxy tip is used with strict diametric tolerances, then attachment reliability improves, but manufacturing complexity increases
Solution Approach 1:
The patent changes the adhesive material from epoxy to instant glue, which has different bonding characteristics. Instant glue provides immediate setting and bonding without requiring precise diametric tolerances during assembly, as the adhesive fills and adapts to minor dimensional variations, thus reducing manufacturing precision requirements while maintaining attachment reliability
Solution Approach 2:
The instant glue acts as an intermediary substance that mediates between the atraumatic tip and the guidewire shaft. It provides a compliant bonding layer that accommodates minor dimensional discrepancies without requiring strict tolerances, thereby maintaining reliable attachment while simplifying manufacturing
3Object-affected harmful factors
If epoxy tip is used, then atraumatic protection is achieved, but material cost increases
Solution Approach 1:
The patent replaces expensive epoxy material with inexpensive instant glue (cyanoacrylate adhesive). The instant glue is applied in a metered amount that is cost-effective for single-use applications, significantly reducing material costs while providing sufficient atraumatic protection for the surgical procedure
Solution Approach 2:
The material parameter change from epoxy to instant glue fundamentally alters the cost structure. Instant glue is less expensive per unit, requires no oven curing equipment, and can be applied directly during assembly, reducing both material cost and manufacturing overhead while maintaining the necessary protective function
4Quantity of substance
If metered amount of glue is used, then material efficiency improves, but monitoring difficulty increases
Solution Approach 1:
The instant glue is applied in a metered amount that self-regulates through its immediate setting characteristics. The adhesive automatically bonds the atraumatic tip to the guidewire shaft without requiring external monitoring or adjustment, as the instant curing action provides immediate feedback on bonding status, eliminating the need for separate monitoring processes
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 new guidewire design allows for faster assembly and inspection, reduces material costs, and enhances the reliability of the atraumatic tip attachment, ensuring effective navigation within anatomical passageways without damaging tissues.
Implementation Method 1
The atraumatic tip may be attached to a distal end of the hollow tube with an adhesive
Data Source
AI summary
A method is used to manufacture a surgical guidewire that includes an outer coil assembly, a position sensor, a communication wire, an adhesive, a core wire, a hollow tube, and an atraumatic tip. The outer coil assembly has an outer coil that extends distally from a proximal coil retainer to a distal coil retainer. The position sensor is located distally within the outer coil assembly and is configured to be in communication with a processor via the communication wire. The core wire is between an outer coil proximal portion and the hollow tube. A distal end of the hollow tube is bonded to the atraumatic tip. The method includes affixing the atraumatic tip to the distal end of the hollow tube with the adhesive. The adhesive is constructed of instant glue.