Double-Bevel Fluid Applicator for Uniform Medical Device Coating
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Solution Overview
Problem
Traditional coating methods for medical devices often result in flawed or uneven coatings, leading to inaccuracies in drug delivery and material waste, particularly when applying coatings to complex shapes like balloon catheters.
Innovation Solution
A coating apparatus with a fluid applicator featuring a double-bevel design, including a first face angled between 15 to 75 degrees and a second intersecting face, combined with a rotation and axial motion mechanism, allows for uniform coating application and minimizes excess material left on the device surface, reducing waste and ensuring consistent active agent distribution.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If traditional dip coating methods are used, then the coating process is simple to implement, but the coating uniformity and manufacturing precision deteriorate
Solution Approach 1:
The coating applicator is segmented into multiple faces (first face and second face) with different orientations. The first face applies coating material at an angle during rotation, while the second face collects excess material, creating a segmented functional approach that improves uniformity while maintaining process simplicity
Solution Approach 2:
The invention introduces a dimensional change by orienting the first face at an angle (15-75 degrees) relative to the axis of rotation, rather than perpendicular to it. This angular orientation in a new dimension allows the coating material to be deposited more uniformly along the surface during rotation, transforming the coating pattern from radial to linear distribution
2Device complexity
If traditional coating methods are used, then the equipment is simple, but the drug delivery precision deteriorates
Solution Approach 1:
The coating applicator segments the coating application and collection functions into separate faces. The first face deposits coating material containing the drug at a controlled angle, while the second face collects excess material, ensuring precise drug delivery without requiring complex dosing equipment
Solution Approach 2:
The second face of the coating applicator acts as a feedback mechanism by collecting excess coating material during rotation. This self-regulating feature ensures that only the appropriate amount of drug-containing coating is deposited, providing inherent dose control without complex feedback equipment
3Productivity
If traditional coating methods are used, then the coating application is fast, but the material waste increases
Solution Approach 1:
The coating applicator is segmented into a first face for application and a second face for collection. During rotation, the second face continuously collects excess coating material, preventing waste while maintaining high-speed coating application. The collected material can be reused, further reducing waste
Solution Approach 2:
The second face of the coating applicator serves as an intermediary between the coating material source and the device surface. It intercepts and collects excess material before it can be wasted, acting as a mediator that redirects material flow to reduce loss while maintaining coating speed
Data Source
AI summary
Embodiments of the invention include apparatus and methods for coating drug coated medical devices. In an embodiment, the invention includes a coating apparatus including a coating application unit. The coating application unit can include a fluid applicator having a lengthwise axis and a width. The fluid applicator can include a tip comprising a first face across the width of the fluid applicator. The first face of the fluid applicator can be oriented at an angle of from about 15 to about 75 degrees with respect to the lengthwise axis of the fluid applicator. The fluid applicator can define a second face intersecting the first face. The coating apparatus can further include a rotation mechanism and an axial motion mechanism. Other embodiments are also included herein.