Catheter Shaft Braid Attachment for Stable Structural Integration
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Solution Overview
Problem
Conventional methods for integrating structural elements in medical catheters, such as reinforcing assemblies and articulation structures, often result in insufficient mechanical stability, variability in outer diameter, and localized stiffness or weakness, impairing catheter performance and maneuverability.
Innovation Solution
The integration of structural elements is enhanced by mechanically connecting them to the exposed portions of the catheter shaft's reinforcing braid, achieved through selective removal of the polymeric jacket and welding or adhesive processes, ensuring a secure bond without compromising flexibility or stiffness.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If adhesives or thermal bonding are used to integrate structural elements, then the structural elements can be anchored to the catheter shaft, but the mechanical stability and durability are insufficient in high stress regions
Solution Approach 1:
The patent replaces chemical bonding (adhesives) and thermal bonding methods with a mechanical connection system. The structural element features a mechanical connector that directly engages with the reinforcing braid through interlocking geometry, eliminating reliance on chemical or thermal bonding processes. This mechanical engagement provides superior strength and durability in high-stress regions by distributing loads through direct physical contact and geometric interlocking rather than through adhesive bonds that can degrade over time.
Solution Approach 2:
The patent employs a composite connection system combining the structural element's mechanical connector with the catheter shaft's reinforcing braid (typically metal wires embedded in polymer). This composite approach leverages the high strength-to-weight ratio and flexibility of the metal braid while maintaining the overall polymer construction of the catheter shaft. The mechanical connector is designed to distribute stresses across multiple braid wires, creating a hybrid connection that combines the advantages of both metal and polymer materials.
2Ease of manufacture
If adhesives or thermal bonding are used to integrate structural elements, then the structural elements can be anchored to the catheter shaft, but the outer diameter varies and localized stiffness or weakness is created
Solution Approach 1:
The patent replaces adhesive and thermal bonding processes with a pure mechanical connection system. The mechanical connector integrates with the reinforcing braid through direct physical engagement, eliminating the need for additional bonding materials or thermal processing steps. This approach maintains consistent outer diameter because the connector is contained within the catheter shaft's existing structure, and no external bonding agents are applied that would alter the dimensions. The connection is achieved through the mechanical interlocking of the connector with the braid, preserving the smooth external profile.
Solution Approach 2:
The patent applies local quality by concentrating the structural reinforcement exactly where needed within the catheter shaft, rather than requiring uniform bonding across entire sections. The mechanical connector is positioned at specific locations along the shaft to provide targeted support at high-stress regions, while the rest of the shaft maintains its original flexible properties. This localized approach allows precise control over where stiffness is introduced, creating gradual transitions in mechanical properties rather than abrupt changes at bonding interfaces.
3Ease of manufacture
If adhesives or thermal bonding are used to integrate structural elements, then the structural elements can be anchored to the catheter shaft, but the desired gradual transition of mechanical properties is disrupted
Solution Approach 1:
The patent employs dynamic design by making the catheter shaft's mechanical properties adjustable and adaptable rather than fixed. The mechanical connection system allows the structural element to flex and move with the catheter shaft during use, creating a dynamic connection that maintains gradual transitions in stiffness. The mechanical connector is designed to accommodate physiological movements and flexing, allowing the catheter to transition smoothly between different mechanical states without creating rigid bonding interfaces that would disrupt the gradual property changes needed for optimal performance.
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 method provides improved structural continuity and enhanced steering responsiveness, maintaining a smooth profile and optimizing mechanical performance of the catheter.
Implementation Method 1
The mechanical connection is formed by exposing the reinforcing braid by selective removal of the polymeric jacket material
Implementation Method 2
mechanically connecting the braid to the structural element, wherein the mechanical connection comprises a welded connection between the reinforcing braid and the structural element
Data Source
AI summary
A medical catheter and its manufacturing method are presented. The catheter features a shaft with a continuous reinforcing braid and a polymeric jacket. Exposed braid grooves are created by selectively removing portions of the polymeric jacket, enabling a mechanical connection of structural elements directly to the exposed braid. These structural elements, such as a reinforcing assembly or an articulation structure, are securely connected through the mechanical connection at the attachment location. This integration enhances the catheter's stability, maneuverability by establishing a direct, seamless connection between the structural element and the catheter shaft creating a catheter with improved performance. The disclosed invention advances catheter design by providing efficient means of integrating structural elements within the catheter shaft.