Catheter Separated Tip Mold With High-Melting Sheet
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Solution Overview
Problem
There is a need for a simpler and cost-effective method to manufacture catheters with separated tip configurations, as existing techniques complicate the manufacturing process.
Innovation Solution
The method involves positioning cores in a mold cavity with a sheet of material having a higher melting temperature than the molding material, injecting the molding material while maintaining the sheet in tension, and using retractable pin assemblies to minimize core deflection, allowing for the formation of catheters with separated tip configurations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Adaptability or versatility
If traditional extrusion techniques are used to manufacture catheters, then the manufacturing process is simple and cost-effective, but the ability to produce catheters with separated tip configurations is limited
Solution Approach 1:
The catheter tip is segmented into separate first and second tips that can be independently formed and positioned within the mold cavity, allowing for separated tip configurations while using a single injection molding process
Solution Approach 2:
The mold cavity is pre-configured with cores and sheets in specific positions before injection, enabling the formation of separated tip configurations during the molding process without requiring post-processing or complex assembly steps
2Shape
If a sheet of material with higher melting temperature is placed across the end portion of the cavity, then the separated tip configuration is formed, but the manufacturing process becomes more complex
Solution Approach 1:
A sheet of material with higher melting temperature is used as an intermediary element within the mold cavity that defines the separation between tips and allows for the formation of separated tip configurations while maintaining a relatively simple overall mold structure
Solution Approach 2:
The sheet material is positioned only at the end portion of the cavity where tip separation is required, leaving the rest of the mold cavity simple and allowing for easy removal of the sheet after molding
3Stability of the object's composition
If the sheet is maintained in tension during injection, then the separated tip configuration is preserved, but additional control mechanisms are required
Solution Approach 1:
The sheet material is maintained in a tensile state during the injection process through dynamic control of the molding conditions and sheet positioning, ensuring that the separated tip configuration is preserved while using relatively simple tension control mechanisms
4Manufacturing precision
If cores are positioned in the mold cavity to define lumens, then the catheter structure is formed, but core deflection may occur during injection
Solution Approach 1:
The mold cavity is designed with adequate support structures and positioning mechanisms that prevent core deflection during the injection process, ensuring both precise lumen definition and core structural stability without requiring excessive reinforcement
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 simplifies the manufacturing process, reduces costs, and effectively produces catheters with separated tip configurations, enhancing the efficiency of catheter production.
Implementation Method 1
placing a sheet of material having a higher melting temperature than a molding material across the first end portion of the cavity
Implementation Method 2
The first and second cores may be held with one or more retractable pin assemblies to minimize deflection of the first and second cores prior to injecting the molding material into the mold
Implementation Method 3
injecting the molding material into the cavity of the mold
Data Source
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Figure 4A~4B
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AI summary
A method for manufacturing a separated tip catheter includes the following steps: positioning first and second cores in a cavity of a mold, the cavity having a substantially elongated shape and including a first end portion and a second end portion, wherein the first and second cores are oriented substantially parallel to each other; placing a sheet of material having a higher melting temperature than a molding material across the first end portion of the cavity; and injecting the molding material into the cavity of the mold.