Fiber Laser Welding of Medical Balloons With a Compression Sleeve

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Solution Overview

Problem

Current laser welding techniques for medical devices often result in weak bonds, especially when welding thick components, and can cause distortion and expansion issues, particularly with medical balloons having a high equator-to-neck ratio.

Innovation Solution

A system utilizing a fiber laser and a compression sleeve to thermally weld polymeric members with a selected wavelength of radiation that is transmittable through the sleeve and absorbable by the members, providing a strong, hermetic bond while minimizing distortion, using a transmission welding mode that allows for thicker welds without the need for protective layers.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Strength

If current laser welding techniques are used for medical devices, then welding can be performed, but the bonds are weak especially for thick components and distortion and expansion issues occur

Engineering Contradiction:

Improvebond strengthVSAvoiddistortion and expansion

Core Design Contradiction:

StrengthVSManufacturing precision

Solution Approach 1:

A compression sleeve is introduced as an intermediary component between the laser beam and the polymeric members being welded. The sleeve compresses the members together during welding, improving bond strength while the laser parameters are optimized to minimize distortion and expansion of the members

Inventive Principle:

Principle #24Intermediary (Mediator)

Solution Approach 2:

The laser wavelength is specifically selected to be absorbable by the polymeric members while being transmittable through the compression sleeve. This parameter change in wavelength selection, combined with controlled compression force, enables strong bonds without excessive heat-induced distortion

Inventive Principle:

Principle #35Parameter changes

2Ease of manufacture

If laser welding is used for medical balloons with high equator-to-neck ratio, then welding can be performed, but expansion and distortion issues are exacerbated

Engineering Contradiction:

Improvewelding capabilityVSAvoidshape stability

Core Design Contradiction:

Ease of manufactureVSStability of the object's composition

Solution Approach 1:

The compression sleeve is positioned and compression force is applied before the laser welding begins. This preliminary compression stabilizes the balloon structure, preventing distortion and expansion during the subsequent laser heating process

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

By selecting a laser wavelength that is absorbable by the polymer material, the welding process achieves efficient heating with reduced overall energy input, minimizing thermal distortion and expansion of the balloon structure

Inventive Principle:

Principle #35Parameter changes

3Strength

If transmission welding mode is used with selected wavelength, then strong hermetic bonds are achieved for thick components, but the system complexity increases

Engineering Contradiction:

Improvehermetic bond strengthVSAvoidsystem complexity

Core Design Contradiction:

StrengthVSDevice complexity

Solution Approach 1:

The system uses a selected laser wavelength that is transmittable through the compression sleeve material but absorbable by the polymeric members. This wavelength selection enables transmission welding mode, achieving strong hermetic bonds for thick components without requiring additional protective layers or complex multi-step processes

Inventive Principle:

Principle #35Parameter changes

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 method achieves a strong, hermetic bond with reduced expansion and distortion, particularly effective for medical balloons with high equator-to-neck ratios, providing a smooth, tapered joint and enhancing the reliability of medical device connections.

Implementation Method 1

The energy includes a wavelength of radiation transmittable through the compression sleeve and the first tubular member, and absorbable by the first tubular member and the second tubular member

Methodology Applied

Scientific EffectRadiation transmission and absorption: Absorption (EM radiation)

Implementation Method 2

an energy source comprising a fiber laser configured to deliver energy to the joint region to thermally weld the first tubular member to the second tubular member

Methodology Applied

Scientific EffectLaser heating: Laser

Implementation Method 3

directing, by a fiber laser, an energy beam to the joint region to thermally weld the first member to the second member

Methodology Applied

Scientific EffectThermal conduction: Conduction (thermal)

Data Source

PatentUS20220126401A1Welding method using fiber laser for components of a medical device

Publication Date: 2022.04.28 MEDTRONIC INC

AI summary

A system includes a first tubular member comprising a first polymer and a second tubular member comprising a second polymer. The first tubular member defines a lumen configured to receive at least a portion of the second tubular member therein to define a joint region. The system further includes a compression sleeve configured to receive at least a portion of the first tubular member at the joint region and an energy source comprising a fiber laser configured to deliver energy to the joint region to thermally weld the first tubular member to the second tubular member. In some examples, the energy includes a wavelength of radiation transmittable through the compression sleeve and the first tubular member, and absorbable by the first tubular member and the second tubular member.