Automated Balloon Layer Forming Apparatus
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Solution Overview
Problem
The manual application of a film outer layer to inflatable balloon catheters is prone to inconsistencies due to operator variability and varying material properties, making it challenging to achieve a smooth and consistent working surface.
Innovation Solution
An automated apparatus is designed to form a balloon layer by gripping and stretching a film layer over an expanded base balloon, using a mandrel, grippers, and actuators to ensure consistent and reliable application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If manual application of film outer layer is used, then operator flexibility is maintained, but consistency and reliability of the working surface deteriorate due to operator variability
Solution Approach 1:
The patent replaces manual mechanical application with an automated mechanical system consisting of a mandrel, grippers, and actuators. The apparatus mechanically stretches and applies the film layer uniformly around the base balloon, eliminating operator variability while maintaining operational control through automated mechanisms.
2Device complexity
If manual film application is used, then equipment complexity is reduced, but manufacturing precision and reliability worsen due to operator variability
Solution Approach 1:
The apparatus is designed to perform the film application process autonomously without requiring continuous operator intervention. The actuators automatically control the grippers to stretch and position the film layer, while the mandrel provides structural support and alignment, enabling the system to serve itself in completing the consistent application of the outer layer.
3Manufacturing precision
If automated apparatus with multiple actuators is used, then manufacturing precision and consistency improve, but device complexity increases
Solution Approach 1:
The mandrel serves multiple functions simultaneously: it provides structural support for the base balloon, acts as an anchor for the film layer, guides the stretching process, and maintains geometric alignment. The grippers also perform dual functions of gripping the film and applying controlled stretching force. This multi-functionality reduces the need for separate dedicated components, thereby managing complexity while achieving precision.
4Productivity
If automated stretching process is used, then productivity and consistency improve, but ease of operation worsens due to reduced operator intervention
Solution Approach 1:
The apparatus employs dynamic actuators that can adjust the stretching process in real-time based on the material properties of the film and the geometry of the base balloon. The system transitions from static manual application to a dynamic automated process where the actuators can modify stretching speed, force, and positioning to optimize both productivity and operational control.
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 apparatus enables the formation of a balloon layer with improved consistency and reliability, reducing operator intervention and enhancing the smoothness and uniformity of the working surface.
Implementation Method 1
The apparatus may also include a heated die. The heated die may include a tapered notch configured for receiving and heating a portion of the balloon layer adjacent a transition from a cone of the base balloon to a neck of the base balloon.
Data Source
AI summary
An apparatus is for forming a balloon layer, such as on an expanded base balloon. The apparatus includes a mandrel supporting the expanded base balloon. At least one gripper is provided for gripping the balloon layer, and an actuator is for stretching the balloon layer over the expanded base balloon, such as by moving the at least one gripper. Related methods for forming a balloon layer are also disclosed.