Deflectable Catheter High Modulus Fiber Puller Element

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Solution Overview

Problem

Conventional puller wires in deflectable catheters tend to weaken and break due to crimping or soldering methods, leading to fatigue and premature failure, especially when used with control handles providing greater throw or pulley mechanisms.

Innovation Solution

A puller element made of high modulus fiber material, such as polymeric or ceramic fibers, is used with a wrapped configuration to engage the distal tip member, providing enhanced durability and elasticity, and is secured using mechanical stops or adhesives to prevent excessive wear.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If crimping or soldering methods are used to anchor the puller wire, then the puller wire is securely attached to the distal tip member, but the puller wire is weakened and subjected to fatigue and premature breakage

Engineering Contradiction:

Improvepuller wire strengthVSAvoidpuller wire durability

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The patent replaces the mechanical crimping/soldering anchoring system with a wrapped configuration where the puller wire is wrapped around an anchor pin and secured with adhesive. This substitution eliminates the need for crimping tools and soldering processes that cause wire damage, while still achieving secure attachment through the combination of mechanical wrapping and chemical bonding.

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

The patent introduces an anchor pin as an intermediary component between the puller wire and the distal tip member. The anchor pin serves as a mediator that the wire wraps around, distributing the attachment force and eliminating the need for direct crimping or soldering of the wire to the tip member, thereby preserving wire integrity.

Inventive Principle:

Principle #24Intermediary (Mediator)

2Strength

If the puller wire is wrapped around an anchor pin, then the puller wire is securely anchored, but the puller wire work-hardens and loses elasticity leading to premature breakage

Engineering Contradiction:

Improvepuller wire anchoring strengthVSAvoidpuller wire elasticity

Core Design Contradiction:

StrengthVSStability of the object's composition

Solution Approach 1:

The patent changes the material parameter of the puller wire from conventional metal (stainless steel or Nitinol) to high modulus fiber material. This material parameter change allows the wire to be wrapped around the anchor pin without work-hardening, as the fiber material maintains its elasticity and does not undergo the same plastic deformation process that metal wires experience during wrapping.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent uses composite construction by combining the high modulus fiber puller wire with adhesive material to create a composite anchoring system. The fiber wire provides tensile strength and elasticity, while the adhesive provides additional bonding to prevent slippage, creating a synergistic attachment that preserves wire properties.

Inventive Principle:

Principle #40Composite materials

3Ease of operation

If conventional metal puller wire is used, then the puller wire can be manipulated by control handles, but the puller wire is prone to fatigue and breakage due to repeated manipulation

Engineering Contradiction:

Improvecontrol handle manipulationVSAvoidpuller wire durability

Core Design Contradiction:

Ease of operationVSReliability

Solution Approach 1:

The patent changes the material parameters of the puller wire from conventional metal to high modulus fiber material with specific properties (tensile strength of 300-1500 ksi, tensile modulus of 5000-20000 ksi). These parameter changes enable the wire to withstand repeated manipulation by control handles without fatiguing or breaking, while maintaining the necessary flexibility for operation.

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

The patent employs the high modulus fiber material's ability to recover its original shape after deformation, allowing the puller wire to be manipulated repeatedly without permanent damage. The fiber material's elastic properties enable it to discard temporary deformations from handling and return to its original state, preventing cumulative fatigue.

Inventive Principle:

Principle #34Discarding and recovering

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

The high modulus fiber puller element maintains elasticity and durability, reducing the risk of breakage and improving the catheter's deflection performance, especially with control handles that provide more throw or employ pulley mechanisms.

Implementation Method 1

the high modulus fiber puller element maintains elasticity and durability

Methodology Applied

Scientific EffectElasticity: Elasticity

Implementation Method 2

wrapped configuration that engages with the distal tip member

Methodology Applied

Scientific EffectFriction: Friction

Data Source

PatentUS8540696B2Deflectable catheter with a high modulus fiber puller element

Publication Date: 2013.09.24 BIOSENSE WEBSTER INC

AI summary

A deflectable catheter includes a catheter body, an intermediate section, a tip electrode and a control handle for deflecting the catheter by manipulation of a puller element that is made of a high modulus fiber material and extends through the catheter body and the intermediate section. The proximal end of the puller element is housed in the control handle and the distal end of the puller element is in a wrapped configuration and engages with a distal tip member or the intermediate section.