Catheter Shaft Conductive Pathway Integration
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Solution Overview
Problem
Medical devices, such as catheters, require electrically conductive pathways to facilitate electrical conduction and signal transmission, but existing methods struggle to effectively integrate these pathways within polymeric materials while maintaining structural integrity and conductivity.
Innovation Solution
The integration of electrically conductive wires or media within a polymeric tube using an extrusion process, where the conductive elements are embedded within a single layer of polymeric material, forming a continuous molecular structure, and additional conductive pathways are created using conductive ink or media applied along the catheter shaft.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If electrically conductive wires or media are integrated within a polymeric tube using traditional methods, then electrical conduction is achieved, but structural integrity and reliability of the conductive pathway are compromised
Solution Approach 1:
The patent combines the polymeric tube and electrically conductive wire into a single integrated structure using extrusion. The wire is embedded within the polymeric material during the extrusion process, creating a unified component where the polymeric material surrounds and protects the conductive pathway. This merging eliminates separate assembly steps and ensures the wire remains securely positioned, improving reliability while maintaining manufacturing simplicity.
Solution Approach 2:
The patent creates a composite structure by integrating an electrically conductive wire within a polymeric tube through extrusion. The resulting device combines the electrical conductivity of the wire with the mechanical properties and flexibility of the polymeric material. This composite approach allows the conductive pathway to be both reliable and structurally sound, resolving the contradiction between reliability and complexity.
2Reliability
If electrically conductive pathways are embedded within polymeric material, then electrical conduction is provided, but manufacturing precision and positioning accuracy are difficult to achieve
Solution Approach 1:
The patent applies preliminary action by preparing the conductive wire and polymeric material before extrusion, ensuring proper alignment and positioning. The wire is pre-positioned within the extrusion path, and the extrusion process is controlled to deposit the polymeric material uniformly around the wire. This preliminary preparation ensures precise positioning of the conductive pathway within the final product, achieving both reliability and manufacturing precision.
3Adaptability or versatility
If multiple conductive pathways are integrated within the catheter shaft, then electrical functionality is enhanced, but device complexity and manufacturing difficulty increase
Solution Approach 1:
The patent merges multiple conductive pathways into the polymeric tube using a single extrusion process. Multiple wires are simultaneously embedded within the polymeric material as it is extruded, creating an integrated structure that provides enhanced electrical functionality. This approach allows multiple conductive pathways to be incorporated without proportionally increasing manufacturing complexity, as they are all processed together in one operation.
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 solution enables reliable electrical conduction and signal transmission along the catheter shaft, enhancing the functionality of medical devices by providing a durable and efficient conductive pathway, suitable for various medical procedures.
Implementation Method 1
an extrusion die including a body having a first diameter, which tapers down to a nose having a second diameter, the nose including a central opening having a longitudinal axis and one or more side openings extending radially inward into the central opening from a exterior surface of the nose, the extrusion die including a central bore longitudinally aligned with the central opening of the nose, the nose further including one or more lumens radially arranged around the central opening of the nose and extending parallel to the longitudinal axis of the central opening; feeding one or more electrically conductive members through the one or more lumens of the nose; and flowing a polymeric material both around the exterior surface of the nose and through the central opening of the nose
Data Source
AI summary
Medical devices having electrically conductive pathways are disclosed. More particularly, the disclosure is directed to catheter shafts including an electrically conductive wire embedded in a polymeric tube. The disclosure is also directed to catheter shafts including an electrically conductive media coextruded in a polymeric tube. The disclosure is also directed to catheter shafts including electrically conductive pathways formed with electrically conductive ink, paste, adhesive and/or epoxy.