Catheter Tip Separation via Composite Strip Bonding
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Solution Overview
Problem
Existing methods for manufacturing catheters with separated tip configurations face challenges in creating distinct, movable tip members that can maintain bi-directional fluid flow effectively during hemodialysis procedures, particularly in ensuring strong bonding between different materials while allowing for the separation of lumens at the distal end.
Innovation Solution
The method involves extruding a thermoplastic material through a die to form a catheter body with a septum between two lumens, inserting a strip with different bonding capabilities between the lumens, and using a combination of mechanical and chemical bonding to create separated tip members, where one section of the strip does not bond with the extrusion material, allowing for the formation of distinct, movable tips.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If a strip with uniform bonding capability is used throughout its length, then bonding strength with extrusion material is maximized, but separation of tip members cannot be achieved
Solution Approach 1:
The strip is designed with spatially varying bonding properties: the proximal portion has bonding capability matching the extrusion material for strong attachment, while the distal portion has reduced or incompatible bonding capability to enable separation. This local differentiation of material properties resolves the contradiction between achieving strong bonding and enabling separation.
2Ease of manufacture
If the same material is used for both bonding and separation sections of the strip, then manufacturing simplicity is maintained, but functional differentiation is lost
Solution Approach 1:
The strip is constructed as a composite structure with at least two different materials: a bonding material in the proximal portion that chemically or mechanically bonds to the extrusion material, and a separation material in the distal portion that does not bond or has reduced bonding capability. This composite approach enables functional differentiation while maintaining manufacturing feasibility.
3Stability of the object's composition
If extensions are formed during extrusion, then material distribution is improved, but additional post-processing steps are required
Solution Approach 1:
The extensions formed during extrusion are removed in a post-processing step through cutting or grinding. This extraction of the extensions eliminates the complexity they introduce while preserving the benefit of improved material distribution achieved during the extrusion process.
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 enables the creation of catheters with effectively separated tip members that maintain structural integrity and bi-directional fluid flow, enhancing the efficiency of hemodialysis procedures by ensuring strong bonding and precise separation of lumens at the distal end.
Implementation Method 1
The extrusion material may be extruded with an extruder heated before the extrusion process, and/or cooled after the extrusion process.
Implementation Method 2
some catheters are formed by extruding molten polymer material through a die
Implementation Method 3
The first material is capable of forming a covalent bond with the extrusion material. The chemical bond formed between the first material and the extrusion material may have an attractive bond greater than the ionic forces of the first material and the extrusion material, i.e, an integral bond.
Data Source
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AI summary
A method for manufacturing a separated tip catheter having a separated tip configuration includes the steps of: extruding an extrusion material through a die to form a catheter including a catheter body having a proximal end and a distal end and defining a first lumen and a second lumen, the catheter body having a septum positioned between the first and second lumens; and feeding a strip into the die so that the strip is positioned between the first lumen and the second lumen along a length of the catheter, the strip having a first proximal section formed of a first material capable of bonding with the extrusion material and a second distal section formed of a second material incapable of bonding with the extrusion material.