Medical Device Braid Coating for Catheter Tip Stability
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Solution Overview
Problem
The combination of braids and soft polymer tips in medical devices can lead to undesirable flaring and migration of braid filaments within the polymer material, which affects the performance and reliability of intracorporal medical devices.
Innovation Solution
A medical device design featuring a braid with an end portion coated using a first polymeric material with a higher melting point temperature to secure the filaments, followed by a second polymeric material with a lower melting point temperature applied to the coated end, using heat attachment techniques to prevent flaring and ensure stability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If a braid is combined with a soft polymer tip material, then the medical device achieves flexibility and softness at the tip, but the braid filaments flare and migrate within the polymer material
Solution Approach 1:
The braid filaments are coated with a polymeric material before the soft polymer tip material is applied. This preliminary coating action prevents the filaments from flaring and migrating when the soft tip material is subsequently applied, allowing the device to maintain both flexibility and braid stability.
Solution Approach 2:
A polymeric coating material is introduced as an intermediary between the braid filaments and the soft polymer tip material. This intermediary layer prevents direct interaction that would cause flaring, while allowing the soft tip material to provide flexibility. The coating acts as a barrier that maintains filament stability while enabling tip softness.
2Shape
If the end of the braid is disposed within the soft polymer material, then the device achieves a smooth tip surface, but the braid ends flair inwardly and/or outwardly through the polymer surface
Solution Approach 1:
The braid filaments are pre-coated with a polymeric material before the soft polymer tip material is applied. This preliminary coating prevents the filaments from flaring through the tip surface, allowing the device to maintain both a smooth tip surface and reliable filament containment.
Solution Approach 2:
A thin polymeric coating film is applied to the braid filaments. This flexible film contains the filaments within the soft polymer tip material, preventing them from flaring through the surface while maintaining the smooth external shape and flexibility of the tip.
3Stability of the object's composition
If a polymeric coating is applied to the braid to prevent flaring, then the braid filament stability improves, but the complexity of the manufacturing process increases
Solution Approach 1:
The polymeric coating application is combined with the existing manufacturing process for applying the soft polymer tip material. By integrating these steps, the manufacturing process complexity is minimized while still achieving braid filament stability through the protective coating.
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 effectively reduces the tendency of braid filaments to flare into the polymer material, enhancing the structural integrity and reliability of medical devices like catheters by maintaining the integrity of the polymeric coating and preventing filament movement.
Implementation Method 1
the first polymeric material attaches the braid filaments together
Implementation Method 2
a first polymeric material having a first melting point temperature
Implementation Method 3
attaching the second polymeric material can include heating the second polymeric material to a temperature that is below the first melting point temperature such that during the attaching of the second polymeric material, the first polymeric material remains in a solid state
Data Source
AI summary
Alternative design, material, manufacturing method, and use for medical devices, such as catheters, catheter shafts and the like. An example includes a medical device, such as a catheter shaft, including an elongated tubular braid comprising a plurality of filaments and including an end portion coated with a first polymeric material having a first melting point temperature, wherein the first polymeric material attaches the braid filaments together. A second polymeric material having a second melting temperature lower than the first melting point temperature may be attached to the coated end portion of the braid. In some embodiments, the underlying a first polymeric material may reduce the tendency of the braid to flair into the second polymeric material. Other examples relate to methods of making such medical devices, such as a catheter shaft, of the like.