Catheter Hub Insert Assembly for Adhesive-Free Leak Prevention
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Solution Overview
Problem
Existing medical catheter assembly methods rely on adhesives and injection molding, which introduce variability, mess, cost, and complications, and are prone to leaks.
Innovation Solution
A friction and interlocking design is used to connect a catheter member to a shaft, eliminating the need for adhesives and injection molding, providing a secure fit and visual/tactile feedback for correct assembly.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If adhesives and injection molding are used to connect catheter components, then assembly can be achieved, but variability, mess, cost, and complications increase along with leak risk
Solution Approach 1:
The patent replaces chemical bonding methods (adhesives) and complex injection molding processes with a purely mechanical friction-fit connection system. The hub and catheter shaft connect through interlocking geometric features that create a secure mechanical bond without requiring adhesives or complex molding operations, thereby eliminating mess and simplifying manufacturing while maintaining reliability
Solution Approach 2:
The catheter assembly is divided into separate components (hub and catheter shaft) that can be manufactured independently and then connected through a friction-fit interface. This segmentation allows for simplified manufacturing of individual parts while achieving reliable assembly through the mechanical connection, reducing overall complexity and eliminating the need for complex injection molding of integrated assemblies
2Ease of manufacture
If adhesives and injection molding are used for assembly, then components can be joined, but variability and complications increase
Solution Approach 1:
The patent replaces adhesive-based and injection molding assembly methods with a mechanical friction-fit system that relies on precise geometric interlocking features. This mechanical approach provides consistent, repeatable connections with minimal variability, as the fit is determined by the precision of the molded geometric features rather than by adhesive application consistency or complex molding processes
Solution Approach 2:
The patent optimizes the friction-fit connection by carefully controlling geometric parameters such as the interference fit dimensions, surface roughness, and interlocking feature geometries. By precisely controlling these parameters during molding, the system achieves low assembly variability without requiring complex assembly processes, thereby improving both manufacturing simplicity and precision
3Device complexity
If friction and interlocking designs are used to connect catheter components, then assembly is simplified and leaks are reduced, but additional features are needed to limit rotation and axial movement
Solution Approach 1:
The patent combines multiple functions into the friction-fit connection interface: the same geometric interlocking features that create the friction fit also serve to limit rotation and axial movement. By merging these functions into a single integrated connection mechanism, the system achieves simplified assembly without requiring separate components or additional manufacturing steps for rotation and axial constraints
Solution Approach 2:
The friction-fit connection interface is designed as a universal mechanism that simultaneously provides friction-based holding, rotational constraint, and axial movement limitation. This multi-functional design eliminates the need for separate features or components for each constraint type, thereby simplifying the overall device while maintaining manufacturing ease through a single integrated connection system
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 simplifies assembly, reduces leaks, and facilitates automated processes while ensuring proper alignment and secure attachment of catheter components.
Implementation Method 1
the insert and the member are configured to compress the elongated body between the insert and the member, thus creating a friction fit to secure the elongated body to the member
Data Source
AI summary
In examples described herein, a catheter includes an insert configured to mechanically connect a member (e.g., a hub) to an elongated body (e.g., a catheter shaft). In some examples, the insert includes an insert proximal portion and an insert distal portion, and the member defines a member distal lumen and a member proximal cavity. The insert distal portion is configured to be inserted into the elongated body and the member distal lumen is configured to receive a portion of the elongated body. The member proximal cavity is configured to receive the insert proximal portion such that the insert proximal face and the member proximal face are aligned. In some examples, when the insert proximal portion is positioned in the member proximal cavity, the insert proximal portion is configured to anchor the insert within the member proximal cavity to limit proximal and distal movement of the insert relative to the member.