Catheter Balloon Molding for Integrated Conductive Electrodes
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Solution Overview
Problem
The integration of electrical components on balloon catheters is challenging due to size, planar geometry, and mechanical properties, leading to detachment and potential patient injury, and the limited size and shape of electric fields generated by existing electrodes.
Innovation Solution
A method and system for integrating conductive elements on catheter balloons using a molding process, involving a mold with conductive materials and polymeric materials, where conductive and non-conductive materials are arranged in layers to define circuits, and passive electrodes are used to extend and focus electric fields.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrical components are integrated on balloon catheters using conventional methods, then the catheter can perform tissue sensing and ablation functions, but the electrical components may detach or flake off during navigation and use, causing patient injury
Solution Approach 1:
The patent combines the electrical components and the balloon catheter into a single integrated structure using a molding process. The conductive material is deposited into a mold cavity, then polymeric material is expanded to contact and bond with the conductive material, creating a unified component that prevents detachment during navigation and use.
Solution Approach 2:
The polymeric material acts as an intermediary between the conductive material and the balloon surface. When the polymeric material is expanded, it creates a mechanical bond that secures the electrical components to the balloon catheter, preventing flaking and detachment while allowing the components to perform their intended functions.
2Length of moving object
If electrodes are made small and planar to fit on balloon catheters, then the catheter can be minimally invasive, but the size and shape of the electric field is limited
Solution Approach 1:
The patent introduces passive electrodes that extend beyond the active electrodes in the radial dimension. These passive electrodes are not directly connected to the pulsed field generator but are positioned to extend the spatial footprint of the electric field, thereby increasing the treatment area without increasing the size of the actively controlled components.
Solution Approach 2:
The passive electrodes serve multiple functions: they extend the electric field coverage area, focus the field distribution, and work in conjunction with the active electrodes to achieve comprehensive tissue ablation. This multi-functionality allows small active electrodes to achieve large effective treatment zones.
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
Stable integration of conductive elements on catheter balloons, preventing detachment and enhancing the size and shape of electric fields for effective tissue ablation and sensing.
Implementation Method 1
expanding the polymeric material to place the polymeric material in contact with the conductive material
Implementation Method 2
stable integration of conductive elements on catheter balloons, preventing detachment
Implementation Method 3
passive electrodes are used to extend and focus electric fields
Data Source
AI summary
The present invention advantageously provides a molding device with conductive material for creating a catheter balloon with conductive elements, and methods and systems for manufacturing the catheter balloon with conductive elements. An exemplary method for coupling a plurality of conductive elements to an expandable element may include placing a first portion of a mold proximate a second portion of the mold to define a casting cavity. Conductive material may be deposited into the casting cavity. Polymeric material may be inserted into the casting cavity. The first portion of the mold may be secured to the second portion of the mold. The polymeric material may be expanded to place the polymeric material in contact with the conductive material.