Catheter Lumen Coating Using Positive Displacement Flow
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Solution Overview
Problem
Traditional methods for coating the inner diameter of medical tubes face limitations in material waste, control, consistency, scalability, and introduce bubbles or imperfections, necessitating a more precise and consistent coating method.
Innovation Solution
A positive displacement system is used to introduce and drain coating solutions into the lumen of tubes, ensuring uniform coating application, utilizing components like piston pumps and peristaltic pumps, with specific coatings such as polyaziridine, polyurethane, polyacrylate, polysaccharide, and polyacrylic acid, and hydrophilic coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of substance
If vacuum techniques are used to draw coating solutions into the lumen, then coating application is achieved, but material waste increases and control over coating volume is poor
Solution Approach 1:
The patent inverts the traditional vacuum-based coating approach by using positive pressure to push coating solution through the lumen. Instead of drawing coating material in with vacuum (which causes waste and poor control), the system uses a pump to positively displace a precise volume of coating solution through the tube, eliminating material waste and improving volumetric control.
Solution Approach 2:
The patent replaces the vacuum mechanical system with a positive displacement pump system. The pump mechanically pushes the coating solution through the lumen with controlled pressure and flow, providing precise control over the volume and rate of coating application, thereby eliminating the material waste and control issues associated with vacuum techniques.
2Manufacturing precision
If vacuum techniques are used for coating, then coating application is achieved, but consistency and uniformity of coating thickness are compromised
Solution Approach 1:
By inverting from vacuum suction to positive pressure displacement, the system achieves consistent and uniform coating thickness. The positive displacement pump delivers a controlled, steady flow of coating solution that uniformly coats the lumen surface, eliminating the variability and imperfections caused by vacuum techniques.
Solution Approach 2:
Replacing the vacuum system with a positive displacement pump provides mechanically controlled, consistent delivery of coating solution. The pump's regulated pressure and flow rate ensure uniform coating thickness and high reliability across multiple coating applications.
3Reliability
If vacuum-based methods are used, then coating is applied, but bubbles or imperfections are introduced during the process
Solution Approach 1:
Inverting from vacuum to positive pressure eliminates bubble formation. The gentle, controlled positive pressure push avoids the violent suction and pressure changes of vacuum methods that trap air and create imperfections, resulting in bubble-free, high-quality coatings.
Solution Approach 2:
The positive displacement pump system replaces the problematic vacuum mechanism, providing smooth, controlled pressure that prevents air entrapment and bubble formation during coating application, thereby improving coating quality and eliminating harmful imperfections.
4Productivity
If traditional vacuum coating methods are used, then coating application is achieved, but scalability and simplicity are reduced
Solution Approach 1:
Inverting to positive pressure displacement simplifies the system architecture and enhances scalability. The pump-based system is more easily integrated into automated production lines and can be scaled to handle multiple tubes simultaneously, improving productivity while reducing operational complexity.
Solution Approach 2:
Replacing the complex vacuum system with a positive displacement pump reduces device complexity. The pump system is mechanically simpler, easier to maintain, and more amenable to automation and scaling for high-volume production, thereby improving both productivity and simplicity.
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 method provides precise control over coating volume, ensuring uniform and consistent low-friction surfaces in medical catheters, improving procedural efficiency and reducing material waste.
Implementation Method 1
introducing a first coating solution into the lumen of the tube using a positive displacement system
Implementation Method 2
the positive displacement is provided by one or more of a piston pump(s)
Implementation Method 3
the positive displacement is provided by one or more of peristaltic pump(s)
Data Source
AI summary
The present invention relates to a method for coating the lumen of a tube using fluid displacement techniques. In some embodiments, the method involves introducing a first coating solution into the lumen of the tube using a positive or negative displacement, draining the excess solution to leave a film on the inner surface, and curing the film to form a uniform coating. In some embodiments, the displacement system can include a piston pump, peristaltic pump, and/or syringe. In some embodiments, a first coating solution may comprise a mixture of polyaziridine and either polyurethane or polyacrylate, while a second coating solution may comprise polysaccharide and/or polyacrylic acid and may be hydrophilic. Additional steps may include applying multiple layers, coating both the inner and outer surfaces of the tube, and/or using gas to drain the coating solution. In some embodiments, multiple tubes can be coated simultaneously using a manifold assembly.