Composite Medical Balloon Hybrid Outer Layer Design
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing medical balloon manufacturing processes are complicated and costly, often resulting in inconsistent seams and undesirable longitudinal fins due to the manual cutting of outer layers, which can affect the precision and reliability of medical balloon expansion in procedures like angioplasty.
Innovation Solution
A composite medical balloon design featuring a hybrid layer with a tube covering the barrel portion and a spiral wrapping for the tapered portions, using materials like polyamide and polyether block amide, which avoids the need for complex cutting and ensures seamless transitions, and optionally includes fiber layers for enhanced structural integrity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If manual cutting of outer layer is used to form radially divided segments, then the tapered end can be covered more precisely, but the process becomes complicated and costly with inconsistent seams and longitudinal fins
Solution Approach 1:
The outer layer is divided into radially spaced apart segments that are separated at least at the tapered end, allowing each segment to be independently positioned and attached to precisely cover the tapered end without requiring complex manual cutting and seam formation
Solution Approach 2:
The segments are formed with gaps between them in the radial dimension, eliminating the need for longitudinal seams while maintaining precise coverage of the tapered end through strategic positioning of each segment
2Ease of manufacture
If manual cutting and seam formation is used, then outer layer can be shaped to fit tapered portions, but the manufacturing process becomes entirely manual and costly
Solution Approach 1:
The outer layer segments are pre-formed with the desired shape and dimensions before attachment to the balloon, allowing for standardized manufacturing processes and eliminating the need for complex on-demand cutting and shaping operations
Solution Approach 2:
The segmented outer layer design allows for replication of standard segment components, enabling consistent manufacturing through repeated production of identical or standardized segment units rather than custom manual formation for each balloon
3Reliability
If seams are formed in the outer layer, then the tapered portions can be covered, but longitudinal fins and inconsistent results occur
Solution Approach 1:
The harmful longitudinal seams are completely removed from the design by using radially spaced segments with gaps between them, eliminating the source of longitudinal fins and inconsistent results while maintaining functional coverage of the tapered end
Solution Approach 2:
The gaps between segments that would normally be considered defects are intentionally designed and positioned to eliminate harmful longitudinal fins, transforming what could be structural weaknesses into features that prevent harmful effects while maintaining precise tapered end coverage
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
The composite balloon design provides a cost-effective, consistent, and reliable solution with improved structural integrity and expanded precision, minimizing the risk of longitudinal extension and distension during medical procedures, while allowing for differential material properties across the balloon regions.
Implementation Method 1
A hybrid layer is adhesively attached to the balloon. The hybrid layer comprises a tube for covering the barrel portion, a first spirally wrapped ribbon of material for covering the first tapered portion, and a second spirally wrapped ribbon of material for covering the second tapered portion.
Data Source
AI summary
A composite medical balloon includes a base balloon with first and second tapered portions (108) and a barrel portion (106) therebetween. The base balloon includes one or more fiber layers. A hybrid layer is applied over the base balloon, such as over the fiber layer. The hybrid layer includes a tube (70) for covering the barrel portion (106) and a spiral wrapping (80) for covering one or both of the first and second tapered portions (108). Related methods of forming of such a balloon are also disclosed.