Movable Tapered Mandrel for Catheter Flared End Extrusion
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Solution Overview
Problem
Current methods for manufacturing tubular medical devices with flared ends, such as catheters, are cumbersome and costly, lacking efficiency and automation in the production process.
Innovation Solution
A method involving extruding a tube and immediately forming a flared end using a moveable tapered mandrel, which is then moved away to prevent interference with the rest of the tube, allowing for integrated and efficient production without additional heating steps, reducing handling complexity and material stress.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If a stationary tapered mandrel is used to form the flared end, then the flared end can be formed consistently, but the rest of the extruded tube cannot be produced without interference and additional heating/cooling steps are required
Solution Approach 1:
The patent applies the dynamics principle by making the tapered mandrel movable rather than stationary. The mandrel is advanced along with the extruded tube to form the flared end, then retracted to allow production of the rest of the tube without interference. This dynamic adjustment eliminates the need for additional heating/cooling steps and simplifies the overall production process while maintaining consistent flared end formation.
2Shape
If the tapered mandrel remains in position during extrusion, then the flared end is formed, but the extruded tube cannot be produced
Solution Approach 1:
The movable tapered mandrel is advanced during extrusion to form the flared end shape, then retracted to allow continuous production of the rest of the tube. This dynamic positioning enables both flared end formation and tube production without interference, significantly improving productivity.
Solution Approach 2:
The production process is segmented into two distinct phases: first, the tapered mandrel is advanced to form the flared end of the tube; second, the mandrel is retracted to allow production of the rest of the tube. This segmentation allows each phase to be optimized independently, ensuring both flared end quality and overall production efficiency.
3Shape
If separate heating and cooling steps are added, then the flared end can be formed, but the production process becomes more time-consuming and costly
Solution Approach 1:
The patent merges the flared end formation with the extrusion process itself. By using a movable tapered mandrel that advances with the extruded tube, the flared end is formed during extrusion without requiring separate heating and cooling steps. This integration eliminates time-consuming post-processing operations and reduces production cycle time.
Solution Approach 2:
The movable tapered mandrel is positioned and advanced before the extrusion process begins, preparing the tooling in advance. This preliminary positioning allows the flared end to be formed immediately during extrusion without requiring subsequent heating or cooling steps, thereby reducing overall production time.
4Shape
If the tube is handled separately after extrusion, then the flared end can be formed, but the risk of material breakage increases and handling complexity increases
Solution Approach 1:
The flared end formation is merged with the extrusion process, eliminating the need for separate handling steps. The movable tapered mandrel forms the flared end in-situ during extrusion, reducing the risk of material breakage and simplifying handling operations.
Solution Approach 2:
The extrusion process itself performs the flared end formation through the movable tapered mandrel, making the system self-sufficient. This self-service approach eliminates the need for external handling operations that could damage the material, thereby improving reliability and reducing breakage risk.
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 approach results in a faster, more cost-effective, and higher-quality production process with reduced risk of material breakage and improved control over material properties, as the flared end is formed in-line with extrusion, simplifying handling and eliminating the need for separate gluing or repeated heating and cooling.
Implementation Method 1
extruding a tube by pushing tube material though an extrusion nozzle
Implementation Method 2
pushing the extruded end over a conical or frusto-conical mandrel during simultaneous heating, and the thus formed part is thereafter immediately cooled in order to obtain a permanent deformation
Data Source
AI summary
Disclosed are a method and an apparatus for manufacturing a medical tubular object, such as a catheter, for insertion into a body passageway. The method comprises the steps of extruding a tube by pushing tube material though an extrusion nozzle and cutting the extruded tube at a predetermined length. Further, an initial part of the extruded tube is advanced onto a tapered mandrel arranged adjacent the extrusion nozzle such that a flared end is formed, and after a predetermined length of the extruded tube has been advanced onto the tapered mandrel, the tapered mandrel is moved away from the extrusion nozzle to prevent that the rest of the extruded tube is expanded by the tapered mandrel.