Injectable Foam Generation with Independent Liquid-Gas Flow Control

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Solution Overview

Problem

Existing methods for producing injectable foam for medical treatments lack flexibility in adjusting foam properties while ensuring consistency and reproducibility, leading to variability and safety concerns.

Innovation Solution

A method and device that allow independent delivery of liquid and gas to a foam producing structure, enabling adjustment of foam density, concentration, and volume without sacrificing consistency or safety, using separate pathways and controlled delivery mechanisms.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If foam is generated using traditional batch methods (Tessari or brush beating), then flexibility in adjusting foam density and concentration is achieved, but variability between batches and physicians increases

Engineering Contradiction:

Improveflexibility in adjusting foam density and concentrationVSAvoidconsistency and reproducibility of foam properties

Core Design Contradiction:

Adaptability or versatilityVSManufacturing precision

Solution Approach 1:

The foam generation process is segmented into separate liquid and gas delivery pathways, each controlled independently. This segmentation allows precise control over the liquid-to-gas ratio, enabling consistent foam properties while maintaining flexibility in adjusting density and concentration parameters.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The system transitions from static batch preparation to dynamic continuous flow generation. By controlling the flow rates of liquid and gas separately through regulated delivery mechanisms, the system can dynamically adjust foam properties in real-time while maintaining batch-to-batch consistency through standardized delivery parameters.

Inventive Principle:

Principle #15Dynamics

2Manufacturing precision

If pressurized canister systems are used, then consistency and reproducibility of foam properties improve, but flexibility in adjusting foam density and concentration is lost

Engineering Contradiction:

Improveconsistency and reproducibility of foam propertiesVSAvoidflexibility in adjusting foam density and concentration

Core Design Contradiction:

Manufacturing precisionVSAdaptability or versatility

Solution Approach 1:

The system replaces fixed pressurized canisters with dynamic flow-controlled delivery mechanisms. By independently regulating liquid and gas flow rates, the system maintains consistent foam quality through controlled generation while allowing flexible adjustment of density and concentration by modifying flow parameters.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The system enables adjustment of foam properties by changing delivery parameters (flow rates, pressures) rather than requiring different pre-filled canisters. By controlling the liquid-to-gas ratio through regulated delivery, the system achieves both consistency through standardized parameters and flexibility through adjustable flow rates.

Inventive Principle:

Principle #35Parameter changes

3Ease of operation

If air is used as the gas component in foam, then ease of operation is improved, but safety concerns increase due to potential gas embolism

Engineering Contradiction:

Improveavailability of gas sourceVSAvoidgas embolism risk

Core Design Contradiction:

Ease of operationVSObject-affected harmful factors

Solution Approach 1:

The system replaces air with physiologically acceptable inert gases (such as nitrogen-free medical gases) that are safer for intravenous administration. The controlled delivery system ensures these gases are delivered in a regulated manner, maintaining ease of operation while eliminating the harmful effects of nitrogen-containing air.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

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

Provides flexible and reproducible production of injectable foam with precise control over properties, ensuring safety and effectiveness for various medical applications.

Implementation Method 1

liquid and gas are combined to produce foam

Methodology Applied

Scientific EffectMixing:

Implementation Method 2

combining of a solution of sclerosing agent with gas until foam is formed

Methodology Applied

Scientific EffectAeration: Aeration

Data Source

PatentUS12502179B2Method and device for generating injectable foam

Publication Date: 2025.12.23 BOSTON SCI MEDICAL DEVICE LTD

AI summary

The present invention relates to methods and devices for production of injectable foams, such as those used in the treatment of varicose veins and other venous disorders. The method requires the delivery or supply of foamable liquid sclerosing agent and a suitable gas or a gas mixture to a foam producing structure in which the liquid and gas are combined to produce foam, wherein the liquid is delivered independently of the delivery of gas. Devices for producing injectable foam comprise a foam producing structure in which liquid and gas are combined to produce foam, the structure comprising an inlet for liquid and gas and an outlet for foam; a liquid pathway in communication with the inlet; and a gas pathway in communication with the inlet, characterised in that the liquid pathway comprises a means for delivering liquid through the liquid pathway independently of gas delivery through the gas pathway. In preferred embodiments, the delivery of liquid and/or gas is controlled with volumetric pumps.