Balloon Catheter Continuous Curing and Drying Process
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Solution Overview
Problem
Existing methods for manufacturing balloon catheters using thermosetting resin are costly and complex, with limitations in continuous production, potential defects from asymmetric balloon formation, and high investment requirements for automation, which hinder efficient and cost-effective mass production.
Innovation Solution
A method combining drying and curing processes after release agent application, involving extrusion of a first tube with an inflation lumen, non-contact release agent spraying, thermal curing, and coating with a balloon material using a continuous process, where a spray restriction film and heating elements are used to manage release agent residuals and ensure efficient curing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a balloon is formed through a dipping process using liquid silicone, then the balloon can be cured and attached to the catheter tube, but the catheter tube must be kept exactly perpendicular to the sea level until the balloon is cured, causing asymmetric balloon defects and making mass production impossible
Solution Approach 1:
The patent replaces the manual mechanical positioning system (keeping the catheter tube perpendicular to sea level) with an automated rotational positioning mechanism. The catheter tube is rotated to a predetermined angle during the dipping process, eliminating the need for manual perpendicular alignment and enabling automated mass production while maintaining consistent balloon symmetry.
Solution Approach 2:
The patent introduces dynamic rotational movement during the dipping process. Instead of static perpendicular positioning, the catheter tube is rotated to a predetermined angle and maintained at that angle during curing. This dynamic positioning approach enables automated control and consistent balloon formation for mass production.
2Ease of manufacture
If an extruded tube is first extruded more thinly than the final product thickness, then overlay extrusion can be performed to produce catheters with embedded balloons, but the first extruded tube must be cut and processed through multiple intermittent steps, preventing continuous production
Solution Approach 1:
The patent implements continuous production by eliminating the cutting and intermittent processing steps. The extruded tube is continuously fed through the overlay extrusion process without being cut into segments. The release agent is applied continuously, and the balloon formation occurs continuously as the tube moves through the extrusion die, enabling uninterrupted mass production.
Solution Approach 2:
The patent applies the release agent to the extruded tube before the overlay extrusion process begins. This preliminary action prepares the surface for balloon formation in advance, allowing the tube to be directly fed into the extrusion die without intermediate cutting or processing steps, thus enabling continuous production.
3Productivity
If laser perforation is used to create an inflation lumen, then the catheter can be produced continuously, but soot remains on the perforated area and the tube may catch fire during the manufacturing process
Solution Approach 1:
The patent extracts the inflation lumen formation process from the laser perforation step. Instead of using laser to burn through the tube wall (which creates soot and fire risk), the inflation lumen is formed by the overlay extrusion process itself, where the balloon material is extruded to enclose the lumen. This eliminates the harmful effects of laser perforation while maintaining continuous production capability.
4Productivity
If automation equipment is invested in to improve production efficiency, then the existing manual processing process can be automated, but manufacturing cost increases due to equipment investment
Solution Approach 1:
The patent merges multiple separate processes (extrusion, release agent application, and balloon formation) into a single integrated overlay extrusion process. This consolidation eliminates the need for separate automation equipment for each step, achieving production efficiency through process integration rather than through expensive multi-equipment automation.
Solution Approach 2:
The overlay extrusion process performs multiple functions simultaneously: it forms the balloon structure, creates the inflation lumen, and applies the balloon material coating. This multi-functionality reduces the need for specialized automation equipment for each individual operation, lowering overall equipment investment while maintaining high productivity.
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 enables rapid, cost-effective, and defect-free production of balloon catheters by integrating curing and drying into a continuous process, reducing manufacturing time and costs, and allowing for higher production speeds without contamination risks.
Implementation Method 1
a process of thermally curing a resin and drying the release agent using a heater
Implementation Method 2
drying the release agent using a heater
Implementation Method 3
a first extruder (20) which extrudes a thermosetting resin using a tube manufacturing mold (8) to manufacture a first tube (14)
Implementation Method 4
a release agent spraying device (22) which alternately sprays a release agent on a predetermined part on an outer periphery of the first tube (14)
Data Source
Figure 1
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Figure 3a
AI summary
The present invention relates to a method of manufacturing a balloon catheter using a thermosetting resin. The present invention aims to provide an economical method of being capable of very promptly manufacturing a balloon catheter using a thermosetting resin through a continuous process, in which a drying process and a curing process are combined, after release agent application using the curing characteristics of a thermosetting resin.