Etched Pre-bending Channels in Medical Cannula Shafts

Resolve Bottlenecks,
Find Innovative SolutionsGenerate Solutions

Solution Overview

Problem

Existing medical devices for inserting or implanting sensors into skin or subcutaneous tissue face challenges in cost-effective manufacturing, system integration, and minimizing skin damage during insertion.

Innovation Solution

A cannula design featuring a hollow shaft formed from flat material with etched pre-bending channels, allowing for reduced bending forces and simplified production, along with a folded sidewall and cutout for guiding sensors, and a sharp tip design with tapered cutting edges to reduce skin trauma.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If the shaft is formed by traditional bending methods from sheet material, then the structural integrity is maintained, but the bending forces required are high and tool life is reduced

Engineering Contradiction:

Improvestructural integrityVSAvoidbending forces and tool life

Core Design Contradiction:

StrengthVSEase of manufacture

Solution Approach 1:

Pre-bending channels are etched into the sheet material before the actual bending process, creating predetermined bending lines that guide the folding process. This preliminary action reduces the bending forces required during manufacturing while maintaining the structural integrity of the final shaft structure

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The local thickness of the sheet material is reduced along the pre-bending channels through etching, changing the physical parameters of the material at specific locations. This creates zones of reduced material thickness that require lower bending forces while preserving the overall strength of the shaft

Inventive Principle:

Principle #35Parameter changes

2Ease of operation

If the sensor layout is angled with respect to the sensor shaft, then the sensor can be inserted into the body, but the substrate layout becomes more difficult to produce

Engineering Contradiction:

Improvesensor insertion capabilityVSAvoidsubstrate layout production

Core Design Contradiction:

Ease of operationVSEase of manufacture

Solution Approach 1:

Instead of creating an angled sensor layout on the substrate, the invention inverts the approach by creating a folded shaft structure that achieves the same functional result. The sensor remains in a straightforward linear layout on the flat substrate, while the shaft folding creates the necessary angular relationship for sensor insertion into the body

Inventive Principle:

Principle #13The other way round (Inversion)

3Productivity

If the cannula is designed for high-volume production of miniaturized parts, then cost efficiency is improved, but manufacturing complexity increases

Engineering Contradiction:

Improvehigh-volume production capabilityVSAvoidmanufacturing process complexity

Core Design Contradiction:

ProductivityVSDevice complexity

Solution Approach 1:

Traditional mechanical bending and forming processes are replaced with chemical etching to create pre-bending channels and complex shaft geometries. This substitution enables high-volume production of miniaturized cannula parts with consistent precision while reducing manufacturing complexity and cost

Inventive Principle:

Principle #28Mechanics substitution (Replace mechanical system)

Solution Approach 2:

Multiple manufacturing operations are merged into a single etching process that creates pre-bending channels, cutting edges, and structural features simultaneously. This consolidation reduces the number of separate manufacturing steps required for high-volume production

Inventive Principle:

Principle #5Merging (Combining)

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 design enables cost-effective, high-volume production of miniaturized parts with reduced skin damage and improved system integration, facilitating efficient sensor insertion and removal.

Implementation Method 1

the shaft has at least one longitudinal pre-bending channel provided in the sheet material, wherein the thickness of the sheet material is reduced along the pre-bending channel

Methodology Applied

Scientific EffectEtching:

Data Source

PatentUS11627897B2Medical device and process for manufacturing

Publication Date: 2023.04.18 ROCHE DIABETES CARE INC

AI summary

This disclosure concerns a medical device and a method for its production, wherein the device comprises a cannula having an elongated hollow shaft and a sharp tip provided at a distal end of the shaft, wherein the shaft is formed as a bent part from a sheet material and confines an interior passage which has a lateral slit opening, and wherein the shaft has at least one longitudinal pre-bending channel provided in the sheet material, wherein the thickness of the sheet material is reduced along the pre-bending channel and a sidewall of the shaft is folded over the pre-bending channel.