Intravascular Stent Seamless Wire Jointing
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Solution Overview
Problem
Traditional intravascular stents face issues such as gaps between connected wire ends allowing blood penetration, uneven force distribution due to increased connection diameter, poor flexibility, and inadequate radiopaque performance leading to high costs and potential dislodgment during surgery.
Innovation Solution
The stent is woven with at least eight wires, featuring aligned and jointed free ends with cutting portions that match each other's diameter, covered by a coupling tube for seamless connection, and incorporates radiopaque wires or coupling tubes for enhanced imaging and reduced material costs.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional side-by-side jointing of wire free ends is used, then connection is achieved, but gaps exist between jointed ends allowing blood penetration
Solution Approach 1:
A coupling tube is introduced as an intermediary component to cover and seal the joint portion where wire free ends are connected. The coupling tube prevents blood from penetrating through gaps between jointed wire ends, thereby eliminating the harmful effect while maintaining the connection function.
Solution Approach 2:
The wire free ends are pre-processed with cutting portions (such as semi-cylindrical or concave-convex structures) before assembly. This preliminary action creates precise matching surfaces that enable tight fitting when joined, reducing gaps and improving the seal before the coupling tube is applied.
2Reliability
If traditional connection method increasing connection portion diameter is used, then wires are connected, but uneven distribution of radial force and axial force occurs
Solution Approach 1:
The invention changes the dimensional parameters of the connection portion by using cutting portions on wire ends that create a joint portion with diameter identical to the wire diameter. This parameter change ensures uniform stress distribution while maintaining connection integrity.
3Measurement precision
If traditional radiopaque rings or marks are added to stent, then radiopaque performance is achieved, but processing requirements increase and stent diameter increases affecting stress distribution
Solution Approach 1:
The coupling tube serves multiple functions: it seals the joint portion to prevent blood penetration, provides structural support, and incorporates radiopaque material to enable imaging. This multi-functionality eliminates the need for separate radiopaque components, reducing complexity while achieving radiopaque performance.
Solution Approach 2:
The radiopaque function is merged into the coupling tube structure itself. The coupling tube is made with radiopaque material or contains radiopaque elements, combining the sealing function and imaging function into a single component, thereby reducing the number of parts and processing steps.
4Measurement precision
If radiopaque weaving wires are used throughout the stent, then radiopaque performance is achieved, but costs increase and precious metal is wasted
Solution Approach 1:
Radiopaque material is applied locally only to the coupling tube and specific wire portions that require imaging visibility, rather than throughout the entire stent structure. This localized application achieves sufficient radiopaque performance for surgical positioning while minimizing the quantity of expensive precious metal used.
5Ease of manufacture
If cylindrical stent structure is used, then manufacturing is simplified, but topical compression or insufficient support occurs on irregular blood vessel inner wall
Solution Approach 1:
The stent structure incorporates flexibility through its wire construction and coupling tube design, allowing it to dynamically adapt to the irregular inner wall of blood vessels. The structure can deform and conform to the vessel geometry while maintaining support function, bridging the gap between simple cylindrical manufacturing and complex adaptive geometry.
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 configuration prevents blood penetration, ensures uniform force distribution, improves flexibility and appearance, and provides excellent radiopaque performance while matching the blood vessel's inner wall, reducing stress and costs.
Implementation Method 1
The cutting portions of the two free ends that are aligned and jointed together are fixed by laser welding.
Implementation Method 2
the coupling tube and the joint portion are fixed by laser welding or clamping deformation
Data Source
Figure 1
Figure 2a~2c
Figure 3
AI summary
Disclosed herein is an intravascular stent for being implanted into blood vessels and a method for manufacturing the same. The intravascular stent is woven by at least one weaving wire, and the stent is in a tubular structure. The at least one wire has an even number of free ends, and the free ends of the at least one wire are aligned and jointed together with each other, which have cutting portions. The cutting portions of the two free ends that are aligned and jointed with each other match each other to make the two free ends be engaged into a joint portion with a diameter identical to that of the wire. The intravascular stent has seamless connection, and the distribution of radial force and axial force of the free ends is uniform, leading to convenience for laser welding. Moreover, the intravascular stent has great flexibility, excellent operability and perfect appearance.