Catheter Shaft Transition Structure for Smooth Braid Joining
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Solution Overview
Problem
Joining proximal and distal catheter shafts of different materials and properties in medical catheters is challenging due to inconsistent methods like thermal bonding and adhesive bonding, leading to abrupt mechanical property changes and impaired positioning and performance.
Innovation Solution
A medical catheter design with a flexible shaft comprising a proximal portion, distal portion, and transition portion, where the proximal and distal reinforcing braids are mechanically connected through a transition portion jacket, reinforced by helical sleeves and anchor rings, allowing for a seamless transition of mechanical properties.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If thermal bonding or adhesive bonding is used to join proximal and distal catheter shafts, then the shafts can be connected, but the connection region exhibits abrupt mechanical property changes in stiffness and strength
Solution Approach 1:
The patent applies local quality by creating a transition portion with gradually varying material composition and structure. The transition portion includes a gradient of polymer materials with changing stiffness properties, allowing mechanical properties to change progressively rather than abruptly. This gradient structure matches the local requirements of different shaft regions while maintaining overall structural integrity.
Solution Approach 2:
The patent utilizes parameter changes by systematically varying the polymer material properties along the length of the transition portion. The stiffness, strength, and other mechanical parameters are continuously adjusted through controlled material composition changes, enabling a smooth transition from the flexible distal shaft to the stiffer proximal shaft without abrupt discontinuities.
2Ease of manufacture
If thermal bonding or adhesive bonding is used to join proximal and distal catheter shafts, then the shafts can be connected, but the manufacturing process is inconsistent and time intensive
Solution Approach 1:
The patent applies segmentation by dividing the catheter shaft into distinct modular components (distal shaft, transition portion, proximal shaft) that can be manufactured separately using optimized processes for each segment. This allows parallel manufacturing of components followed by reliable assembly, improving both manufacturing consistency and reducing overall production time compared to attempting to manufacture the entire shaft as a single integrated piece.
Solution Approach 2:
The patent utilizes composite materials by combining different polymer materials with varying mechanical properties in a controlled gradient structure. The transition portion employs composite construction with multiple material layers or phases that provide tailored mechanical properties, enabling consistent manufacturing through established composite material processing techniques while achieving performance that would be difficult to obtain with homogeneous materials.
3Adaptability or versatility
If proximal and distal catheter shafts of different materials and properties are joined, then catheter performance can be optimized, but abrupt mechanical property changes impede positioning and performance capabilities
Solution Approach 1:
The transition portion is designed with locally optimized material properties that gradually change to match the requirements of adjacent shaft regions. This local quality variation ensures that each section of the catheter has the appropriate mechanical characteristics for its function while maintaining smooth transitions that prevent positioning issues.
Solution Approach 2:
The patent implements continuous parameter changes in the transition portion, where mechanical properties such as stiffness, flexibility, and strength are systematically varied along the length of the transition region. This gradual parameter transition eliminates abrupt changes that would otherwise create positioning difficulties, allowing the catheter to maintain optimal performance across all regions.
Data Source
AI summary
A medical catheter and its manufacturing method are presented, creating a single device from two distinct components. The catheter features a proximal shaft and a distal shaft with distinct polymeric material where the exposed braided structures are mechanically connected at a transition portion, resulting in a single shaft. A reinforcing assembly is integrated into the proximal shaft and includes reinforcing sleeves with helical coils creating a steering wire guidance system, and an anchor ring mechanically connected to the transition portion. The distal shaft incorporates an articulation structure with interconnected elements and steering wire lumens aligned with the reinforcing assembly. The manufacturing process involves selectively removing polymeric jackets of a proximal and distal shaft, exposing the braided structures, and mechanically connecting the braided structures. Such a medical catheter device and method of manufacturing addresses limitations of conventional joining methods, enhancing maneuverability and precision for navigating complex anatomies in various applications.