Segmented Bonding Structure for Catheter Torque Transmission
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Solution Overview
Problem
There is a need for alternative medical devices and manufacturing methods that provide improved design, material, and usage options for intracorporeal medical devices, such as guidewires and catheters, to enhance their performance and versatility in various medical procedures.
Innovation Solution
A medical device comprising a tubular member with slots and a liner, where bonding members are disposed between the tubular member and the liner to secure them together, allowing for enhanced bonding and torque transmission while maintaining flexibility and compatibility with different medical procedures.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If bonding members are disposed between the tubular member and the liner to bond them together, then bonding strength and torque transmission are improved, but device complexity increases
Solution Approach 1:
The bonding structure is segmented into discrete bonding members (adhesive layers, crimp sections, or welding zones) distributed at specific intervals along the catheter length, rather than continuous bonding. This segmentation provides sufficient bonding strength at critical locations while reducing overall complexity and material usage.
Solution Approach 2:
Bonding members act as intermediary elements between the tubular member and the liner, providing a dedicated bonding interface that transmits torque and axial forces while allowing independent selection of materials and bonding methods optimized for each component.
2Force
If bonding members are used to secure the liner to the tubular member, then torque transmission is improved, but manufacturing complexity increases
Solution Approach 1:
Bonding members are pre-positioned or pre-applied to either the tubular member or the liner before final assembly, allowing standardized sub-assemblies to be manufactured separately and then combined. This preliminary action simplifies the final assembly process while ensuring proper bonding locations and orientations.
Solution Approach 2:
The bonding method can be changed along the length of the catheter, with different bonding members (adhesive, crimp, weld) used in different sections to optimize for local requirements such as torque transmission needs, flexibility requirements, and manufacturing capabilities.
3Reliability
If a robust bonding structure is implemented, then device reliability is improved, but flexibility is reduced
Solution Approach 1:
The catheter is divided into bonded sections with bonding members at discrete locations rather than continuous bonding. This allows unbonded sections to maintain full flexibility and conformability for navigation through vessels, while bonded sections provide reliable torque transmission and structural integrity where needed.
Solution Approach 2:
Different bonding characteristics are applied to different sections of the catheter based on local requirements. High-bonding sections provide reliability for torque-critical areas, while low-bonding or unbonded sections maintain flexibility for navigation-critical areas, creating local quality variations that optimize overall performance.
Data Source
AI summary
Medical devices and methods for making and using the same. An example medical device may include a tubular member and a liner disposed within the tubular member. The tubular member may have a plurality of slots formed therein. A space may be defined between the tubular member and the liner. One or more bonding members may be disposed in the space.