Balloon Catheter Integral Channels for Dilation Element Attachment

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Solution Overview

Problem

Conventional balloon catheters face challenges in securely attaching dilation wires or beads due to adhesive detachment issues, especially with compliant materials, and the manufacturing process is cumbersome and messy with adhesives.

Innovation Solution

The balloon catheter features integral channels along its surface for securing dilation elements, which are extruded with the balloon material and can include anchor portions and extensions to securely hold the dilation elements without adhesives, using a method that involves extruding a parison with longitudinal cavities and extensions, and blow molding to form the balloon.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If adhesives are used to secure dilation wires or beads to the balloon surface, then the dilation elements can be attached to the balloon, but the adhesive may detach from the balloon surface allowing the dilation wire and bead to break loose

Engineering Contradiction:

Improveattachment strengthVSAvoidattachment reliability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The balloon surface is segmented into multiple channels that are integrally formed with the balloon material. These channels provide discrete locations for securing dilation elements, distributing the attachment points along the balloon length rather than relying on a single adhesive application area.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The channels are integrally combined with the balloon material through co-extrusion, creating a unified structure where the channels and balloon material form a single piece. This eliminates the interface between separate components (adhesive and balloon surface) that could fail, merging the attachment mechanism into the balloon itself.

Inventive Principle:

Principle #5Merging (Combining)

2Ease of manufacture

If adhesives are used to secure dilation elements to the balloon, then the dilation elements can be attached, but the manufacturing process becomes cumbersome and messy

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidmanufacturing process complexity

Core Design Contradiction:

Ease of manufactureVSDevice complexity

Solution Approach 1:

The channels are co-extruded with the balloon material in a single manufacturing step, merging the channel formation and balloon fabrication into one process. This eliminates separate steps for applying and curing adhesives, simplifying the overall manufacturing process.

Inventive Principle:

Principle #5Merging (Combining)

Solution Approach 2:

The adhesive application step is completely extracted from the manufacturing process. Instead of applying adhesive as a separate operation, the attachment mechanism is built into the balloon structure itself through integral channel formation, removing the source of manufacturing complexity and mess.

Inventive Principle:

Principle #2Taking out (Extraction)

3Adaptability or versatility

If conventional balloons are used without integral channels, then the balloon can be made from simple material, but the dilation elements cannot be securely attached without adhesives

Engineering Contradiction:

Improvedilation element attachment capabilityVSAvoidballoon structure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

The balloon material maintains its base properties throughout, but local regions (the channels) are modified to provide attachment functionality. The channels are formed with specific geometries including cavities and openings that are tailored for securing dilation elements, while the rest of the balloon retains its original material characteristics.

Inventive Principle:

Principle #3Local quality

Solution Approach 2:

The integral channels serve multiple functions: they provide structural support for the balloon, create attachment points for dilation elements, and can be designed with varying geometries to accommodate different types of dilation elements (wires, beads, or combinations) along different portions of the balloon.

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 solution provides a secure and reliable attachment of dilation elements, reducing the risk of detachment and simplifying the manufacturing process by eliminating the need for adhesives, thus enhancing the stability and efficiency of balloon catheter operations.

Implementation Method 1

heating the parison inside a mold and pressurizing the central opening of the parison, the parison thereby expanding against the mold

Methodology Applied

Scientific EffectThermal expansion: Thermal Expansion

Data Source

PatentEP2571560B1Method of forming a balloon with integral retention of a dilation element

Publication Date: 2017.03.01 COOK MEDICAL TECHNOLOGIES LLC

AI summary

A balloon catheter is provided with integral channels for securing dilation elements to the outside of the balloon. The dilation elements have an anchor portion and an intermediate portion that are disposed within first and second longitudinal cavities in the channels. The balloon may be manufactured by extruding a parison and blow molding the parison with the dilation elements installed within the channels.