Drainage Member Windows for Ultrasonic Catheter Tube Welding
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Solution Overview
Problem
Existing urinary catheters face challenges in achieving a strong and stable connection between the catheter tube and the drainage member, such as a funnel, which is crucial for effective urine drainage.
Innovation Solution
The catheter tube and drainage member are ultrasonically welded through windows or recesses in the drainage member, combined with a mechanical interference fit and optional protective sleeve, to create a secure and fluid-tight bond.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If the drainage member is made as a thin-walled structure to reduce complexity and improve ease of manufacture, then the manufacturing precision and structural strength required for a reliable weld connection become difficult to achieve
Solution Approach 1:
The drainage member is pre-formed with integrated windows and recesses during the molding process. The windows are positioned at specific locations on the wall, and recesses are created at the distal end to receive the catheter tube. This preliminary structuring enables subsequent welding operations to be performed with precise positioning without requiring complex post-processing or assembly steps.
Solution Approach 2:
The windows in the drainage member wall serve as intermediary access points that allow welding tools to reach and join the catheter tube to the drainage member through the wall structure. The recesses at the distal end act as intermediary receiving structures that properly position and align the catheter tube for welding, facilitating a reliable connection without requiring the wall to be thick or complex.
2Device complexity
If the wall of the drainage member is made thinner to simplify the structure and reduce material usage, then the ability to achieve a strong and stable weld connection between the catheter tube and drainage member is compromised
Solution Approach 1:
The drainage member wall is segmented by creating windows at specific locations, which divides the wall into distinct regions. This segmentation allows welding operations to be performed through the windows without requiring the entire wall to be thick or structurally complex. The wall maintains sufficient strength in the regions surrounding the windows while allowing access for welding at the window locations.
Solution Approach 2:
The drainage member is designed with localized features including windows at specific wall positions and recesses at the distal end. These local structural modifications provide the necessary strength and welding access at critical locations without requiring the entire drainage member to be thick-walled. The local quality of the wall varies to meet different functional requirements - thin for ease of manufacture, with localized reinforcements and features where strength is needed.
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 method ensures a robust and reliable connection that maintains fluid integrity and ease of handling, enhancing the catheter's functionality and user experience.
Implementation Method 1
The drainage member is welded to the catheter tube through the at least one window
Data Source
Figure 1~2
Figure 3~3A
Figure 3B~4
AI summary
A urinary catheter is disclosed. The urinary catheter comprises a catheter tube having a proximal insertion end and a distal end. The catheter also comprises a drainage member. The drainage member includes a wall having an inner surface and an outer surface. The inner surface defines a drainage lumen having an opening in a proximal end of the drainage member. The distal end of the catheter tube is inserted through the opening of the proximal end of the drainage member and is located in the lumen. The wall of the drainage member has at least one window therethrough. The drainage member and the catheter tube are welded to one another at one or more welding sites in the vicinity of the window(s).