Braided Catheter Shaft Assembly for Stable Steering and Flexibility

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Solution Overview

Problem

Conventional methods of integrating structural elements in medical catheters, such as Bowden assemblies and articulation structures, often result in insufficient mechanical stability and variability in catheter shaft properties due to bonding techniques, which can compromise flexibility and introduce abrupt changes in stiffness.

Innovation Solution

The method involves selectively exposing the reinforcing braid of the catheter shaft by removing a portion of the polymeric jacket to create windows, allowing for mechanical connections of structural elements through the braid using attachment materials, such as adhesives, to establish secure bonds without altering the catheter's flexibility or outer diameter.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If bonding techniques are used to integrate structural elements, then mechanical stability is improved, but flexibility is compromised and abrupt changes in stiffness are introduced

Engineering Contradiction:

Improvemechanical stabilityVSAvoidflexibility

Core Design Contradiction:

StrengthVSEase of operation

Solution Approach 1:

The patent removes a portion of the polymeric jacket to create a window exposing the reinforcing braid, allowing structural elements to be mechanically connected through the braid rather than bonding to the jacket. This extraction of the bonding interface eliminates the stiffness discontinuity while maintaining mechanical stability through direct braid connection.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The reinforcing braid serves as an intermediary structure that enables mechanical connection between structural elements and the catheter shaft. By connecting through the braid rather than bonding to the jacket, the patent achieves stable integration without compromising the gradual transition of mechanical properties along the shaft.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If bonding techniques are used to integrate structural elements, then mechanical stability is improved, but variability in catheter shaft properties is introduced

Engineering Contradiction:

Improvemechanical stabilityVSAvoidconsistency of shaft properties

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

By removing the polymeric jacket to create a window and connecting structural elements directly to the reinforcing braid, the patent eliminates the bonding process that causes variability in outer diameter and localized stiffness. This ensures consistent mechanical properties along the shaft length.

Inventive Principle:

Principle #2Taking out (Extraction)

3Reliability

If adhesives or thermal bonding are used, then structural elements are secured, but outer diameter variability is created

Engineering Contradiction:

Improvesecure bondingVSAvoidouter diameter consistency

Core Design Contradiction:

ReliabilityVSManufacturing precision

Solution Approach 1:

The patent replaces chemical bonding (adhesives) and thermal bonding with a mechanical connection method. Structural elements are mechanically connected through the exposing of the reinforcing braid and use of attachment materials, achieving secure bonding without the outer diameter variability introduced by adhesive or thermal processes.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

4Reliability

If adhesives or thermal bonding are used, then structural elements are secured, but localized stiffness or weakness is created

Engineering Contradiction:

Improvesecure bondingVSAvoiduniformity of mechanical properties

Core Design Contradiction:

ReliabilityVSStability of the object's composition

Solution Approach 1:

The patent removes the polymeric jacket at the connection point to expose the reinforcing braid, allowing structural elements to be mechanically integrated without creating localized stiffness or weakness. This maintains the gradual transition of mechanical properties along the shaft length.

Inventive Principle:

Principle #2Taking out (Extraction)

Data Source

PatentUS20260048233A1Catheter shaft and methods of making a catheter shaft

Publication Date: 2026.02.19 BOSTON SCIENTIFIC SCIMED INC

AI summary

A medical catheter with improved structural integration and performance is disclosed. The catheter features a flexible shaft with a reinforcing braid and a polymeric jacket. Structural elements, such as a reinforcing assembly and an articulation structure, are positioned within the shaft and mechanically connected to the polymeric jacket. The connection is formed by creating windows in the polymeric jacket to expose the underlying reinforcing braid and disposing an attachment material through the windows and the braid into circumferential grooves of the structural elements. The attachment material fills the grooves, interlocking the structural elements with the braid and creating a strong, seamless bond with the polymeric jacket. This approach enhances force transmission, steering control, and overall catheter performance. The mechanical connection can be customized by varying the size, shape, and location of the windows and grooves, making the design adaptable to various catheter configurations and applications.