Catheter Distal Tip Structure for Radiopacity Without Breakage

Solution Overview

Problem

Conventional catheter configurations fail to adequately suppress breakage of the distal tip, particularly when radiopaque material is included, reducing flexibility and increasing the risk of breakage during insertion into curved body lumens or when the distal tip is caught in a constricted part.

Innovation Solution

A medical device with a distal tip containing resin and radiopaque materials, a reinforcing layer connected to the proximal end, and a resin layer with a different material property located distal to the proximal end of the distal tip, enhancing flexibility and visibility while reinforcing the connection point to prevent breakage.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If radiopaque material is included in the distal tip to ensure visibility under radiation, then visibility is improved, but flexibility is reduced and breakage risk increases

Engineering Contradiction:

Improvevisibility of distal tipVSAvoidflexibility of distal tip

Core Design Contradiction:

ReliabilityVSStrength

Solution Approach 1:

The catheter is divided into distinct segments with different material compositions: the distal tip contains radiopaque material for visibility, the intermediate resin layer provides flexibility and stress absorption, and the proximal shaft provides structural support. This segmentation allows each segment to optimize its properties without compromising the whole.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The catheter employs composite material structure where radiopaque material is combined with resin material in the distal tip, and a separate resin layer is positioned between the distal tip and shaft. This composite structure achieves both radiopacity for visibility and sufficient flexibility by distributing mechanical stresses across different material layers.

Inventive Principle:

Principle #40Composite materials

2Strength

If the distal tip is made flexible to prevent breakage during insertion, then flexibility is improved, but visibility under radiation deteriorates

Engineering Contradiction:

Improveflexibility of distal tipVSAvoidvisibility of distal tip

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

The catheter is divided into distinct segments with different material compositions: the distal tip contains radiopaque material for visibility, the intermediate resin layer provides flexibility and stress absorption, and the proximal shaft provides structural support. This segmentation allows each segment to optimize its properties without compromising the whole.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The catheter employs composite material structure where radiopaque material is combined with resin material in the distal tip, and a separate resin layer is positioned between the distal tip and shaft. This composite structure achieves both radiopacity for visibility and sufficient flexibility by distributing mechanical stresses across different material layers.

Inventive Principle:

Principle #40Composite materials

3Strength

If the distal tip is extended between two reinforcing layers to suppress breakage, then breakage resistance is improved, but stiffness gap and breakage risk at connection points increase

Engineering Contradiction:

Improvebreakage resistance of distal tipVSAvoidstability at connection position

Core Design Contradiction:

StrengthVSReliability

Solution Approach 1:

A resin layer acts as an intermediary element positioned between the distal tip and the reinforcing shaft. This intermediate layer serves as a stress-absorbing buffer that mitigates the stiffness gap between the flexible distal tip and the rigid shaft, preventing stress concentration and breakage at the connection point.

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The resin layer is designed with specific material properties (different from both the distal tip and shaft materials) to create a gradual transition in stiffness. This parameter change approach allows smooth mechanical property transition from the flexible distal tip to the rigid shaft, reducing stress concentration at interfaces.

Inventive Principle:

Principle #35Parameter changes

Data Source

PatentUS20260069830A1Medical device

Publication Date: 2026.03.12 ASAHI INTECC CO LTD

AI summary

A medical device includes a distal tip, a first reinforcing layer, and a resin layer. The distal tip contains resin material and radiopaque material and has a material property. The first reinforcing layer is connected to a proximal end of the distal tip. The resin layer is arranged in a radially outward side of the distal tip, has a distal end located distal to the proximal end of the distal tip, and has material property different from the material property of the distal tip.