Balloon Catheter Reinforcement via Segmented Electroforming
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Solution Overview
Problem
Existing balloon catheters face challenges in achieving the required characteristics for specific medical procedures, such as high pressure resistance and blade rigidity, due to limitations in material changes and manufacturing complexities, which affect their performance and ease of use.
Innovation Solution
A balloon catheter with an additional structure directly formed on its inner or outer surfaces, allowing for precise and flexible design, including tubular mesh or linear shapes, that can be secured and deformable, enhancing pressure resistance and blade functionality without compromising crossability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If the balloon wall is thickened to improve pressure resistance, then the pressure resistance is improved, but the crossability through the lesion location deteriorates
Solution Approach 1:
The reinforcement is segmented into discrete circumferential lines rather than a continuous thick wall. Multiple reinforcement lines are distributed around the balloon circumference, providing pressure resistance while maintaining flexibility and crossability through the lesion location.
Solution Approach 2:
The balloon wall has non-uniform thickness with localized reinforcement lines at specific circumferential positions. The reinforcement lines provide enhanced pressure resistance only where needed, while the rest of the balloon wall remains thin to maintain crossability and flexibility.
2Strength
If a resin-reinforced tube is inserted in the balloon for reinforcement, then the pressure resistance is improved, but the manufacturing complexity increases due to precise dimension matching requirements
Solution Approach 1:
The reinforcement structure is merged with the balloon wall itself rather than being a separate inserted component. The reinforcement lines are formed as an integral part of the balloon manufacturing process, eliminating the need for separate tube insertion and precise dimension matching between components.
Solution Approach 2:
The balloon wall serves multiple functions: it provides the basic balloon structure, maintains flexibility for crossability, and incorporates reinforcement lines for pressure resistance. This multi-functionality eliminates the need for separate reinforcement tubes and simplifies manufacturing.
3Strength
If the balloon is thickened to achieve required pressure resistance, then the pressure resistance is improved, but the flexibility and ease of insertion are compromised
Solution Approach 1:
The reinforcement is divided into discrete circumferential lines rather than a continuous thick wall, allowing the balloon to flex and bend between the reinforcement lines while maintaining pressure resistance at the reinforcement locations.
Solution Approach 2:
The balloon wall thickness varies locally with thin sections for flexibility and insertion, and localized thick reinforcement lines for pressure resistance, achieving both properties simultaneously in different regions of the same balloon.
Data Source
AI summary
To provide a new balloon catheter enabling formation of, with high dimensional accuracy and excellent shape adaptability with respect to a balloon, an additional structure such as a blade and a reinforcement member to be additionally provided to the balloon. In this balloon catheter 10 provided with an expandable/contractible balloon 14 on the distal end side of a catheter 12, an additional structure 36 having a prescribed pattern is formed through electroforming or the like directly onto an inner circumferential surface 34 and/or an outer circumferential surface 82 of the balloon 14.